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 Post subject: Big clutch problem, diagnosis needed.
PostPosted: Wed Jul 28, 2010 5:44 pm 
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Joined: Fri Oct 17, 2008 8:12 pm
Posts: 43
Car(s): Susuki SJ- Offroad car, Ford Capri MKIII 1600 Laser
Car had been off the road for 2 weeks whilst i was sorting out the bonnet after having a stag run out on me. Covered the engine bay with tarpooling but it didnt work at all times so rust may be part of the problem.

The first time i drove it once the bonnet was fixed i went out for about 15 minutes and on the way back i went to go from 3rd to 4th and it grinded and wouldnt go into 4th and felt loads of resistance in the pedal. Pushed as hard as i could and it klunked into 3rd, managed to nurse it home until i was about 100 metres away from my house and had to stop at crossroads. couldnt get it into any gear except reverse but as soon as i did it just jolted and stopped.

I thought the clutch might be stuck, but i wouldnt of been able to do 15 minutes of driving in the first place with no problems if it was?

I adjusted the lock nuts where the cable enters the gearbox via the rubber boot but the problem is still there.

PLEASE HELP!!


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Wed Jul 28, 2010 7:05 pm 
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Joined: Tue Jul 20, 2010 9:30 pm
Posts: 79
Car(s): Long term project Capri - far too many mods & far too top secret to discuss at this stage!! ;-) , Daily driver Citreon Xsara estate (my reliable little chug!) Last completed Capri project C71 HHK - 2.8i Special; full rebuild & resto by myself, sold to a guy in Devon last year, most recent vehicle project VW T4 Transporter, converted by myself as a leisure and work vehicle & to promote my business - much like my Capri project
Have you been under the car with someone working the clutch pedal to see if the cable is doing its job properly?

It could be several things, with the faves on my list being either the cable or release bearing. But who knows - it could be the pressure plate, but I'd be surprised. :?


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Wed Jul 28, 2010 7:20 pm 
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Joined: Fri Jun 18, 2010 7:12 am
Posts: 120
Car(s): fordc probe
Could be that the clutch friction plate has broken up. I've seen it several times. Usually there's little or no warning of it happening.


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Wed Jul 28, 2010 7:30 pm 
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Joined: Fri Oct 17, 2008 8:12 pm
Posts: 43
Car(s): Susuki SJ- Offroad car, Ford Capri MKIII 1600 Laser
Friction plates braking up on capris? Could make sense as their was no smell or anything


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Wed Jul 28, 2010 9:19 pm 
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Joined: Mon Jul 28, 2008 7:57 am
Posts: 3219
Location: Kent
Car(s): 1985 Capri 2.0
I'd be inclined to go with Tony and check the cable first, perhaps it has seized with lack of use and maybe some rain in it. It's certainly the easiest and cheapest possibility so start with that!

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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Thu Jul 29, 2010 12:16 am 
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Joined: Fri Oct 17, 2008 8:12 pm
Posts: 43
Car(s): Susuki SJ- Offroad car, Ford Capri MKIII 1600 Laser
Ill have a go at the cable first then, ill work out how to remove it and check it out cos there is alot of slack when its operated.


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Thu Jul 29, 2010 8:34 pm 
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Joined: Fri Oct 17, 2008 8:12 pm
Posts: 43
Car(s): Susuki SJ- Offroad car, Ford Capri MKIII 1600 Laser
Took off the cable and it was fine, ive freed the gearbox from the engine and prop shaft and will remove it tomorow, just the gearstick is still on which is in the way if anyone knows how to take it off? The exhaust is also in the way of the gearbox which could cause some problems.

Had a look in the release forks hole in the bell housing and the pressure plate and bearing look fine, so im thinking the friction plate must of shattered.


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Thu Jul 29, 2010 8:49 pm 
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Joined: Mon Jul 28, 2008 6:50 pm
Posts: 1972
Location: Ipswich, Suffolk
Car(s): 2.0 Cabaret Auto - Soon to be daily driver
2.0 Cameo - Currently being Zetec'd
Peugeot 406 - Daily Driver and dull as!
Gearsticks depends on box type

Type 9 3 bolts and it lifts out the 4 speed box (Type e?) theres a ring that unscrews and it lifts out, its a serrated thing thats sharp as fuck!


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Thu Jul 29, 2010 10:06 pm 
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Joined: Fri Oct 17, 2008 8:12 pm
Posts: 43
Car(s): Susuki SJ- Offroad car, Ford Capri MKIII 1600 Laser
its a 5 speed box, sorry should of said, i think it will come out its just the gearstick is going to be in the way when i try and get it past the exhaust


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Thu Jul 29, 2010 11:02 pm 
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Joined: Mon Jul 28, 2008 6:31 am
Posts: 3588
Location: Lincolnshire
Car(s): Black 2.0S with supercharged bike carbs edit; X(in progress)X NOW FULLY OPERATIONAL AND VERY NAUGHTY. Also a white Laser refurbed & parked up & a spare Eaton behind the easychair:-)
Gear lever screws will probably be Torx head size T44
You'll need the centre tray out so clock to disconnect (don't let the wires short) rubber plug lifted to remove hidden screw in centre etc.
Stick it in gear before removing the lever, click photo below for details:

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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Fri Jul 30, 2010 1:22 am 
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Joined: Fri Oct 17, 2008 8:12 pm
Posts: 43
Car(s): Susuki SJ- Offroad car, Ford Capri MKIII 1600 Laser
Ok cheers, how would i go about getting some of those front end bushings that you replaced on your page? my control arms and anti roll bar have none left whatsoever.

Any idea what gearbox oil i need aswell?


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Fri Jul 30, 2010 8:16 am 
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Joined: Fri Jun 18, 2010 7:12 am
Posts: 120
Car(s): fordc probe
Superflex do a complete range of bushes for the Capri. In my opinion they're the best on the market but make your own mind up on that one.
As for gearbox oil, whenever we drop a gearbox we drain it and refill with ATF (automatic transmission fluid). Gives a smoother gearchange and doesn't drag so much in cold weather.
If you slightly overfill the gearbox it will help lubricate the 5th gear bearing.


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Fri Jul 30, 2010 8:30 am 
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Joined: Mon Jul 28, 2008 6:31 am
Posts: 3588
Location: Lincolnshire
Car(s): Black 2.0S with supercharged bike carbs edit; X(in progress)X NOW FULLY OPERATIONAL AND VERY NAUGHTY. Also a white Laser refurbed & parked up & a spare Eaton behind the easychair:-)
Lots of suppliers stock poly bushes for capris at various prices.
CCI have them, Superpro Europe, and my local village garage are Duraflex stockists who could order them in. Google 'poly bushes' and 'capri'

CAliverpoolfc wrote:
Any idea what gearbox oil i need aswell?


Ford specification is Semi-synthetic transmission oil, I've always used 75W90 without any problems.

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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Fri Jul 30, 2010 5:15 pm 
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Joined: Fri Oct 17, 2008 8:12 pm
Posts: 43
Car(s): Susuki SJ- Offroad car, Ford Capri MKIII 1600 Laser
Alright lads, just got the gearbox and clutch off; turns out one of the springs had came out of the friction disc! Never heard of that one before. Ripped the friction disc apart and put a few dents in the pressure plate. Brilliant.


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Fri Jul 30, 2010 5:37 pm 
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Joined: Mon Jul 28, 2008 7:57 am
Posts: 3219
Location: Kent
Car(s): 1985 Capri 2.0
CAliverpoolfc wrote:
Alright lads, just got the gearbox and clutch off; turns out one of the springs had came out of the friction disc! Never heard of that one before. Ripped the friction disc apart and put a few dents in the pressure plate. Brilliant.



I've had a spring come loose, it was giving me a bit of clutch judder so I investigated. I guess it would have come free if I'd ignored it.

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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Mon Aug 02, 2010 9:48 pm 
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Joined: Fri Jun 18, 2010 7:12 am
Posts: 120
Car(s): fordc probe
Told ya, have seen this a few times, mostly on 2.8i's though.


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 Post subject: Re: Big clutch problem, diagnosis needed.
PostPosted: Wed Aug 04, 2010 3:59 pm 
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Joined: Fri Oct 17, 2008 8:12 pm
Posts: 43
Car(s): Susuki SJ- Offroad car, Ford Capri MKIII 1600 Laser
finished it and its running fine. cheers for the tips on the bushes, will probably order some this week.


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