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Discussion Starter #1
I have a samurai 1.9td. I have just taken the gear box out to replace worn first gear synchro. After much struggling the gear box slipped back in but now I can't seem to get it into gear. I have tightened the cable until there is almost no free play at the release arm. The clutch feels spongy when pressed. Could I have damaged the clutch or spring release putting the gear box back in? Or do I just need to tighten the cable more? Please can any one advise before I take the gear box out again.
 

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there is almost no free play at the release arm
Gauge your "play" at the pedal. Hopefully you just need to adjust the cable tighter, as opposed to having a release bearing / clutch actuation shaft assembly problem, a worn out cable or cable bracket (attachment) issue.
 

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Discussion Starter #3
Thanks Max for advice, I can see the logic . Have tightened clutch at pedal until the bolt almost fell out but still can't get into gear. I will try measuring length of clutch cable to see if it has stretched. When moving her with the engine off I hear a grating noise from the bell housing, never noticed this before?
 

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When moving her with the engine off I hear a grating noise from the bell housing, never noticed this before?
THAT doesn't sound good. Assembly error? :huh:
 

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Gauge your "play" at the pedal. Hopefully you just need to adjust the cable tighter, as opposed to having a release bearing / clutch actuation shaft assembly problem, a worn out cable or cable bracket (attachment) issue.
The "play" is that when you push down on the pedal an till it begins to get get tough ?
 
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