new clutch dragging

[autosurgeon]

my brother bought a 53 plate kia sedona 2.9diesel last year which 2wks ago required a new clutch so he brought it to me and i duly removed the gearbox taking care no to disconnect the hydraulic system but just to unbolt it from the gearbox fitted new clutch kit and reassembled it onlt to find that it wont engage gears when running only if you shut it off first,which results in the cluch dragging!!!.does anyone know if the is any adjustment that can be done as this is driving me up the wall

[pistnbroke]

the operating fork will have to move further forwards to disengage the clutch...were the ends of the forks worn or clutch release bearing replaced...you may be able to extend the rod from the hydraulic cylinder say 3mm by putting a cap on the end ( bit of tubewith blocked off end. you should of course bleed the system...with assistant open bleed on slave cylinder ..push pedal down ..close valve ...repeat a few times ..I just let it piss out on the floor but you could use a tube to catch the fluid.

PS for american readers a 53plate is the second half of 2003 an 03 is the first half etc

[autosurgeon]

thanks for the reply pistnbroke i measure the length of the cylinder rod then subsequently welded and extra 3mm approx to end of the rod but to no avail i then tried a bit of threaded bar fed through the end of the arm with a nut on it to adjust the rod length,and bleed the hell out of the system.still no good!.the clutch kit was a complete set with a new thrust brg so at the moment losing hair at a rate of knots over this b*****d problem

[93fxdl]

a couple of suggestions whilst putting it together did the bearing get missplaced on the fork and did the fork get displaced on the bellhousing also are you sure the clutch cylinders are ok and has something become missplaced in the pedal mechanisim also did you compare new and old parts to make sure they were identical
ttfn glenn

[autosurgeon]

thanks for the reply 93 tried everything i know about mechanical clutches and their hydraulic operation,and came to the conclusion that the new clutch was at fault.so out came the gearbox again!!!,the old,new clutch was made by a company called solid ace, i subsequently replaced it with a quinten hazell make ,reassembled the gearbox and hey presto the damn thing worked fine! hoorah!!!!!!!1.so for all you other sedona owners who fancy doing a clutch go the exta few bob and get a quinten hazell make and save yourself a lot of cursing.