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Clutch lever stuck. 1996 suzuki.

Discussion in 'Suzuki Carry' started by GypsyD, Mar 24, 2018.

  1. GypsyD

    GypsyD New Member

    Hi, I've checked the forum for this particular problem but haven't found anything.
    Tried to go for a drive last week in the truck 1996 (DD51T) when I pushed in the clutch there seemed to be a lot of slack in the cable but I was able to put in gear. Parked the truck to close the garage, when I went to put it into gear again it wouldn't engage. I figured it was the cable so I adjusted that. Then tried to put it into gear again, but what seemed to be happening was the lever on the side of the transmission was stuck and I was just stretching the cable more and more. I had to roll the truck back into the garage, the lever is completely seized can't even move it by hand. So the question is what causes this? I wasn't having any noticeable slippage on the clutch. Maybe I need to replace the clutch? Any Ideas?
     
  2. Jim Nelson

    Jim Nelson Active Member

    It sounds like the throw out bearing is seized up on the tranny shaft. Has it been sitting a lot?
     
  3. fmartin_gila

    fmartin_gila Active Member

    Clutch cable itself may be unraveling a small bit each time you depress the pedal.

    Fred
     
  4. GypsyD

    GypsyD New Member

    I drive the truck about 4 to 5 times a week. It gets lots of use. From what i can tell this was quite sudden, I wasn't having any issues before it completely seized up. So if it is the throw out bearing I guess that would mean, from what I've read I need a clutch kit. Would that be correct?
     
    Last edited: Mar 25, 2018
  5. GypsyD

    GypsyD New Member

    I actually thought it was the cable at first. So I ordered a new one. I didn't receive the source of the problem until installing the new one.
     
  6. Jim Nelson

    Jim Nelson Active Member

    The throw out bearing is mounted on a carrier that slides on the transmission shaft and when you step on the clutch pedal it slides forward and contacts the pressure plate. This disengages the pressure plate from the clutch plate and the bearing allows the engine to keep spinning while taking the transmission out of gear by separating the clutch plate from the pressure plate.
    I'll bet you can find a bunch of you tube videos showing how this works.
     
  7. GypsyD

    GypsyD New Member

    Thanks Jim, yeah I did some digging and I've got my head around how how it works . I guess I'll be ordering a clutch kit monday morning. I usually do most of my mechanic work. But I've never touched the transmission end of things. Would you say the clutch replacement is a doable home job?
     
  8. Jim Nelson

    Jim Nelson Active Member

    I did mine but I have a lift and my truck has a dump bed so that's kind of cheating but I'm an old man with only 1 eye and I got it done.It helps to have a helper as the trans. and transfer case are a little heavy and awkward to handle.a floor jack helps but I think a motorcycle jack would be easier to lift it and you can usually find them cheap on Craig's List,I got one for $30. Good luck.
     
  9. GypsyD

    GypsyD New Member

    Thanks again Jim, I plan on getting into the first of the week and hopefully all goes well. I'm replacing all my gear oil now.
     
  10. AngusII

    AngusII New Member

    Hello,
    Well, there may lay your problem.
    You would not be able to push in the clutch plate by hand using the release lever/arm, it is spring loaded. But you would be able to move the arm/lever for the TO bearings free play. Since, you can not. I would think that it is bound up some were. Is there any play inward/outward at the pivot point/shaft?.
    You may try taping the arm at the pivot point with a deadblow hammer, to see if you can get it to release/move. Or try using a large/long wrench on it for leverage.
    Yet, even if you do get it to release, it may happen again. Are you sure you put the correct length cable in? These days I check every part I pull from a box or wrapper. Mess ups do happen....
    So, it may not be the pressure plate and disc problems. But, it sounds like you may be pulling the trans and TC if you can't jar it loose... But I would check the replacement cable for correctness.
    Good Luck...
     
  11. Jigs-n-fixtures

    Jigs-n-fixtures Active Member

    Clutches can go over enter if not properly adjusted, and stick in the disengaged condition. This might be what is happening to you.
     
  12. AngusII

    AngusII New Member

    Hello,
    Well, the question is how to un-stick it, without pulling the trans??? If possible.
    I have never been inside one of these drivetrains, so I don't have a clue what it would be binding on.. And, of course there is no online pdf files to look at..
    So, Jigs. What is the trick????
     
  13. Jigs-n-fixtures

    Jigs-n-fixtures Active Member

    I only had it happen once, a lot of years ago, and I had to pull the tranny to get at the fingers on the clutch.
     
  14. AngusII

    AngusII New Member

    Hello,
    Heck, that's a bitch... I'm glad I'm not GypsyD....
    Yet, if it's stuck in the disengaged position, the TO bearing shouldn't be up against the pressure plate. Oh well, NMP.
    The mystery of these little beast continues...
    Well, I hope GypsyD can get it done and keep us posted on how it goes.
     
  15. GypsyD

    GypsyD New Member

    Haven't had the time to tear the thing apart yet. Gonna go at it this weekend. As for the clutch lever, it won't move in any direction. So the problem is going to be internal. Step one get it apart, then order parts. It should be an adventure.
     
  16. GypsyD

    GypsyD New Member

    So got the tranny off. That wasn't to bad, I really enjoy working on these trucks. So what I found was it was the clutch lever that was seized. Lots of salt on the roads around here this time of year. Probably what caused it. So some WD40 and some bearing grease and it working great. Throw off bearing is grinding so I'm replacing that and am going to replace the clutch while everything is apart.
     
  17. AngusII

    AngusII New Member

    Hello, Cool. Good for you.
    Well, since you're in there and you have the funds, yes you should replace the clutch system parts. You can always check the wear specs and keep the parts if they are within specs. for back up parts...
    Heck, only $160 for a clutch kit from FG Procurement or $185 from G&R Imports... for the Suzuki DD51T.
    Not that bad of a deal to get your rig back on the road again..
     
  18. fargo9123

    fargo9123 New Member

    hey every one, glad I kept this site book marked this sounds like a problem I have with my 96 carry as this morning i was doing something and stopped to check my mail and when I went to back up it acted as if something were under the wheels, and once I started out on the road I wasn't able to shift gears at all. I can't easily get under the thing since I have a bad back but gonna do it anyway so if there are any other tips I'd sure like to hear
    them! Thanks all!
     
    Last edited: Jun 5, 2018
  19. rumleyfips

    rumleyfips New Member

    I spray the throwout bearing shaft where it goes into the case every few weeks to minimize this problem. Lately it has started sticking on cold ( 5F ) damp days. I wonder if there could be a moisture problem in the cable as well. Has anyone tried to lube and clean the clutch cable ?

    How much should the lever swing? Mine seems to move about 1 inch.

    I don't want to pull the transmission in the middle of a Nova Scotia winter. Got wimpy lately.
     
  20. fargo9123

    fargo9123 New Member

    EH! I worked most of the summer and part of the fall trying to get my truck to work again. I replaced everything related to the clutch but to no avail. I just can't seem to adjust the new cable and now that I've back surgery my truck is sitting there in the cold Nebraska weather! Will be towing to some one who can work on it when weather gets better.
     

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