When the engine is running I CANNOT CHANGE GEARS

Tiny
ELIAS MWALE
  • MEMBER
  • 2000 DAIHATSU TERIOS
  • 1.3L
  • 4 CYL
  • 4WD
  • MANUAL
  • 108,000 MILES
I cannot change gears when the engine is running. But if I stop the engine I can change and move the car. To change to another gear I need to stop the car, which implies that it is a challenge to move in high gears like gear fourth and fifth.

The question is what is the problem? And how can it be solved?
Please help.

Elias Mwale.
Zambia.
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Thursday, December 1st, 2016 AT 7:56 AM

11 Replies

Tiny
CJ MEDEVAC
  • EXPERT
We do not have repair information on your vehicle.

Not knowing the set up

I will give you possibilities that may or may not apply to your vehicle

Mechanical Linkages-look for wear, breakages, even a bent throw-out bearing fork

Hydraulic clutch- look for leaks, system may have air in it (bleed system) This may be the easiest fix if it is the problem.

The clutch master cylinder may be worn out (replace it), the slave cylinder may be worn out (replace).

Let us know what you find!

The Medic
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Thursday, December 1st, 2016 AT 4:24 PM
Tiny
ELIAS MWALE
  • MEMBER
The car uses a cable instead of a hydraulics to pull the folk.
And how does the master or slave cylinders look like and where is it situated?
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Friday, December 2nd, 2016 AT 8:13 AM
Tiny
CJ MEDEVAC
  • EXPERT
If it has a cable, the whole system may be mechanical.

The cable to the fork would take the place of a slave cylinder, therefore I presume there is no clutch master cylinder.

(if there were one, it most likely would be on the firewall on the opposite side of the firewall from the clutch pedal)

Is there a lot of slack in the cable?

Or is the cable so tight that the fork is being pulled (as if you had the pedal pushed in)?

How much (if any) free play in the pedal do you have before you feel the pressure plate being pushed on?

Have you watched the operation of the fork, while someone else pushed the clutch pedal? What does it do?

The Medic
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Friday, December 2nd, 2016 AT 3:55 PM
Tiny
CARADIODOC
  • EXPERT
You don't have those hydraulic parts when you have a cable system. What CJ is suggesting is that cable may have stretched over time. The result is the same as when you don't push the clutch pedal far enough. That will also make it difficult to switch gears.

Another thing you might look for is a lot of cars now that use cables use a toothed rack that drops down onto the pedal when you push that pedal. The idea is as soon as you move the pedal an inch or two, it allows that toothed assembly to drop down and catch on the teeth on the pedal, above its pivot point. From then on, pushing the pedal further tugs on that toothed assembly which is connected to the cable. This arrangement is supposed to keep the cable in constant adjustment. In fact, that system causes more problems than it prevents. Specifically, if the grease that toothed lever rides on gets hardened with age, or cold, it causes that toothed lever to drop too slowly. It doesn't engage until you already have the pedal pushed half way to the floor. To identify this cause, push the clutch pedal only about two inches, hesitate there for a few seconds, then continue to push it the rest of the way. If that works, have the pivot cleaned and relubricated.

Be aware too that you can up-shift without even using the clutch pedal. This isn't recommended for daily driving, but it can allow you to drive using all the gears. Start out in first gear, then hold the engine's speed steady while you slide the transmission out of gear. Hold pressure on the shift lever toward second gear. As engine speed slows down, the transmission will drop into second gear when engine speed matches wheel speed. It will jerk a little, but once you get the hang of it, you be able to shift into any gear when engine speed and wheel speed make the gears in the transmission rotate at the same speed. Race car drivers use this technique a lot because racing clutches can be really hard to push.
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Friday, December 2nd, 2016 AT 4:08 PM
Tiny
ELIAS MWALE
  • MEMBER
@ CJ the clutch moves about an inch or two but not more than that, before I feel the pressure plate. But I can't determine whether their is too much slack or its it's very tight.
On the operation of the fork, I have observed it moving and the pressure plate fingers being when the engine is stationary.
And when the engine is running also managed to see the slightly movement of the fingers but with some squeaking noise.

Thank you I appreciate your feedback
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Sunday, December 4th, 2016 AT 2:58 AM
Tiny
ELIAS MWALE
  • MEMBER
@ Caradiodoc, thank you for your educative information.
The arrangement is that the cable is connected directly from the clutch pedal to the fork. This is a Daihatsu Terios 2000 model manual transmission. There's no toothed rack. So I tried pushing the pedal as you advised but it didn't help.
I would appreciate any further help
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Sunday, December 4th, 2016 AT 4:18 AM
Tiny
KEN
  • ADMIN
Hey Elias

This sounds like the clutch disc has falling apart which will lock the clutch up and not allow it to disengage.

Here is a guide to help you figure it out.

https://www.2carpros.com/articles/clutch-doesnt-work-sometimes-or-not-at-all

Please run some tests and get back to us so we can continue helping you.

Best, Ken

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Sunday, December 4th, 2016 AT 1:07 PM
Tiny
KEN
  • ADMIN
From ELIAS

Hello Ken, Thank you for the response. Now to my surprise as I was preparing myself to dismount the clutch. I started the car with the reverse gear and then forward with gear 3 and moved the car. But as I progressed I observed that it started changing gears properly and then after wards it stopped. Just like that some distance. So I don't know what could have happened on that one.

Sent from Yahoo Mail on Android
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Tuesday, December 6th, 2016 AT 10:45 AM
Tiny
KEN
  • ADMIN
It Could be that the broken part of clutch material could have worked its way out and free from the clutch.
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Tuesday, December 6th, 2016 AT 10:46 AM
Tiny
ELIAS MWALE
  • MEMBER
Hello 2CARPROS,
The car has stopped behaving as I explained. It's now moving okay for the past 2 days I haven't experienced gear change failure. This happened when I drove the car to take some tools in preparation to have it dismantled.
So can I go ahead and dismantle it though its okay or what? I don't know what happened.
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Sunday, December 11th, 2016 AT 8:55 AM
Tiny
KEN
  • ADMIN
Chances are if the problem happened once it will happen again. With that many miles a clutch should be replaced anyway.

Please let us know happens so it will help others.

Best, Ken
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Monday, December 12th, 2016 AT 9:38 AM

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