Hi, having trouble getting the clutch fork pin to go back in its going in so far but sticks out 8mm, theres a notch in the end ive turned it 360 to locate it but still sticks out, what does it locate into could that be causing me probs. Any ideas anyone its a 99 classic

ive had a look in scoobynets search but only removal procedures

 

There's a cotter pin in the RHS of the gearbox case that the cut-out in the end of the pin should locate into.

Have you cleaned the pin, and put a small amount of copperslip/grease on it?

 

I oiled the pin and gave it a tap to ease it in but always stopped with about 8mm still sticking out, should the pin be pushed in with the notch horizontal or vertical

 

I'm pretty sure its vertical mate.
If you get 2 nuts and lock them on to a bolt that fits the thread in the pin and screw it in to the pin till its go's tight you could rotate the pin whilst gently pushing on it to locate it.

 

Ye we were doing that turning while chapping the ratchet still wouldnt slip right in , will grease it right up the morro how hard can i chap it in

 

Does it seem like it is travelling through he clutch fork ok or does it bind up mate?
Not really a good idea to bag to hard as you could notch the hole or roll pin that the bush locates into and then you will be pulling it all back out to file it back to shape or knocking a new role pin in.

 

When I did mine I cleaned up the pin on a wire brush, as there was a lot of crap on it.
Then a bit of copper slip, bolt in the end with a socket and ratchet then pushed through and then turned the ratchet to twist the pin to meet up with the cotter pin.

 

seems to slip in with a good push an can pull it out with a claw hammer, just gets in so far an gets stuck.
will give a good clean an grease it up

 

sounds like either you haven't cleaned it up enough or you have marked it some where and it is binding mate as it should push in and pull out with relative ease so i'd be pulling it out to inspect it as you could suffer more trouble quite quick even if you manage to bash it in there with the clutch feeling funny as the fork won't rotate on the bush right.

 

We couldnt see any marks, scraps or gouges on the pin so hopefully a clean up will help. thanks for the info

 

As said above, you should be able to push the pin into it's location relatively easily by hand, if it's been cleaned and greased.

IIRC, the cotter pin runs horizontally.

Try removing the clutch fork from the bell housing, and check to see if the pin slides through it with no resistance. Then try the pin in the bellhousing, with no clutch fork.
You should be able to see what it's binding on - I reckon it'll be the clutch fork, all caked up with cr@p

 

Hopefully mate but bear in mind the pin is steel and the box is cast so the box would mark and chip before the pin due to it being softer so any damage would be in the box not on the pin but obviously try a clean up first good luck

 

Had another go the day, cleaned it an greased it right up but wouldnt line up was just off line for going into position, moved the fork about nothing changed so pulled the engine back out put the clutch pin through the gearbox without the fork in position and still jammed like before so scrapped and cleaned where the pin locates and with a little tap locked into place so put the engine back in an clutch fork pin is in and done

 

Well done fella,had you marked the hole on the box abit then from miss allignment?

 

No idea min, it had been hitting to the side of the hole we checked the box an pin for marks there wasn't any, the hole it locates into was quite tight so after cleaning it up an bit o grease job done