Clutch Or Gearbox ... Problems

[cmia]

I have some problems with my taxi

Its an

Avensis 99 2.0GS

Basically, when its been cold outside.. or it has been parked up for couple of days, when I start the car and try to select a gear, its very difficult.

I can not select 1st,2,3,4, or 5, however reverse goes in first time.

after some clutch pressing, i can get First gear, but its really notchy,

2nd has the same problem...

However once the car is warm, or drove for afew minutes all is well ...

Some history ....

Basically the cars engine died.....and we sold the car .. as a new / replacment engine would cost 600.00.

..

So .. after he put an engine into the car, my dad decided to buy it back off him ...

I drove it over 500 miles, before I started to experiance problems, with gear shifting.

I have spoke to the guy who installed the engine, and He says that HE .. used our orginal gearbox. (orginal box never had any problems).

Its come to a point where in the cold it is nearly imposible to change gear..

However when the engine is off, I can select any gear ... and goes in first time...

Today .. I put the car in first gear, and kept the clutch down, and started it, It kind of jerked forward slightly... even with the clutch peadle down all the way. Whilst driving it, and standing at the traffic lights, it felt like the car was moving forward really slowly.. but clutch was down all the way..

All the fluids are OK... clutch fluid is OK, gearbox oil is new semi senthic ...

Has anyone got any ideas .. what the problem is ?

[Parva]

I have some problems with my taxi

Its an

Avensis 99 2.0GS

Basically, when its been cold outside.. or it has been parked up for couple of days, when I start the car and try to select a gear, its very difficult.

I can not select 1st,2,3,4, or 5, however reverse goes in first time.

after some clutch pressing, i can get First gear, but its really notchy,

2nd has the same problem...

However once the car is warm, or drove for afew minutes all is well ...

Some history ....

Basically the cars engine died.....and we sold the car .. as a new / replacment engine would cost 600.00.

..

So .. after he put an engine into the car, my dad decided to buy it back off him ...

I drove it over 500 miles, before I started to experiance problems, with gear shifting.

I have spoke to the guy who installed the engine, and He says that HE .. used our orginal gearbox. (orginal box never had any problems).

Its come to a point where in the cold it is nearly imposible to change gear..

However when the engine is off, I can select any gear ... and goes in first time...

Today .. I put the car in first gear, and kept the clutch down, and started it, It kind of jerked forward slightly... even with the clutch peadle down all the way. Whilst driving it, and standing at the traffic lights, it felt like the car was moving forward really slowly.. but clutch was down all the way..

All the fluids are OK... clutch fluid is OK, gearbox oil is new semi senthic ...

Has anyone got any ideas .. what the problem is ?

My guess would be the clutch pressure plate needs replacement. Incidentally, was the gearbox oil changed to semi-synth because of this problem or has the problem occured since the change? I would have said gearbox oil initially but clutch pressure plates can cause problems with gear selection too.

If the gearbox oil was changed to try to rectify the problem then it's time for a new clutch assembly (no point just changing the pressure plate as the entire clutch has to come out). If the problem has occured SINCE the the gearbox oil change then I'd suggest going back to Toyota spec gearbox oil.

[cmia]

the oil is toyotas 75/90

problem was still present before the oil chnage.

[Penfold]

The seals in the clutch master or slave cylinder have worn out. :(

Two things are guaranteed to break on a car when it gets to winter, the Battery and the hydraulic seals but only if they are 'of an age'.

The fact that if you pump the clutch pedal it will go into gear easier when cold and that it is OK when warm is a give away that the problem is hydraulic in nature. Not having the problem when the engine is switched off backs this up.

First job to do is change the fluid in the clutch and to bleed the system. This will either buy you time or if the seals are badly worn then it will just not be able to bleed any air out. (btw - air in a system will make it worse when hot)

If this doesn't cure it then you'll have to change the seals or possible the cylinders if they have become scored by debris in the fluid.

WARNING If the clutch seals have got to this point then seriously consider the braking system as well. It is the same age and made of the same materials. Have it looked at as a priority.

[cmia]

The seals in the clutch master or slave cylinder have worn out. :(

The fact that if you pump the clutch pedal it will go into gear easier when cold and that it is OK when warm is a give away that the problem is hydraulic in nature. Not having the problem when the engine is switched off backs this up.

- Ive looked into this for a couple of days now...

and I have come to some of my own conclusions.

Please correct me if iam wrong.

- Gearbox is fine,

it can select any gear once warm,

and when the engine is off and not running gear selection is fine.

- selecting 1st or 2nd gear on a morning has become extremly difficult.

However I can get reverse .. 1st time, any time .

Today, I pumped the pedal 10>15 times and it would not take a gear, apart from reverse.

Finially when it did take a gear .. it was extemly difficult to get it out.

- If it was an hydralic problem, i think the problems would contiune and prossibly get worse as the car drove,

becuase the fulid would get thinner, etc.

- Ive been to diffrent garages

Some says its the release bearing...

others seem to think its the clutch...

one of them have pointed out it is the spindle, or clutch drag.

- I think it is the release bearing, or clutch drag.

Iam going down the right lines or have I completly lost the plot.

[gazza1286]

Your reasoning seem sound to me.

Have you considered this:- When the engine was replaced with a new/salvage unit it might have been supplied with a clutch attached. This may have had some wear characteristics which didn't match those on the original thrust bearing. This may have resulted in the problems that you are experiencing. just a thought.

As previously mentioned I would suggest replacing ALL three clutch components. Cover/friction plate/release bearing.

[cmia]

Your reasoning seem sound to me.

Have you considered this:- When the engine was replaced with a new/salvage unit it might have been supplied with a clutch attached. This may have had some wear characteristics which didn't match those on the original thrust bearing. This may have resulted in the problems that you are experiencing. just a thought.

As previously mentioned I would suggest replacing ALL three clutch components. Cover/friction plate/release bearing.

I now think the guy who put it in, took the good clutch out /replaced it with diffrent parts.

been looking at this clutch kit.

any ideas ?

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?Vie...416166&rd=1

[gazza1286]

Reputable brand. Reasonable price

[cmia]

Reputable brand. Reasonable price

does any one know how much a Genuine Part would cost from toyota.

It did cost me, 30 quid in gearbox oil! :o

[Parva]

Reputable brand. Reasonable price

does any one know how much a Genuine Part would cost from toyota.

It did cost me, 30 quid in gearbox oil! :o

As I said originally, the clutch pressure-plate can cause the very problems you describe. Wouldn't even like to hazard a guess at Toyota prices! Personally I'd just get a whole new clutch assembly from my local motor factors (friction-plate, pressure-plate and thrust bearing).