Ok so i went had another crack at it but changed a few of the parts over.
I used the fork from the 56a box in my sunny and the new release bearing i had lying around here that was the same size as the others.

And from what it looks like, its worked! Before installing the g/b again i gave the return spring and lever a look over and check to see if they were all operating as they should. The spring was a bit bent out of shape as to where it clamps onto the release bearing so i swapped the spring over from another box also.
The other fork & bearing went in fine and same with the g/b but this time i used a spare 1200 clutch cable rather than the sunnys as I realised that the sunnys cables about 60mm too long.
So for future refrence, dont use a sunnys cable as it wont fit if no mods have been done to the cable.

Tested out the clutch and it seems to have enough throw, havent been for a drive or started the engine with it in gear but it feels like it used to in the sunny with this car/clutch setup.

On that topic, what clutch setups have people got running behind their A series engines? I fear that this may slip a bit with the extra mods now done to my engine...
The 56a box will be the next to go im assuming

CHeers for the input/comments
Dave

Also, can you purchase the reverse light solinoid that goes on the side of the g/b from nissan still?

Quote:OK, so we have a 56A gearbox which came standard behind A12 type engines. Your A series engine has an A12 flywheel, so that matches.
You have an A15 clutch which is the same as the A12 dimentionally, just with higher clamping pressure, so thats cool, but it will not engage.

Well, first things first. With the clutch cable removed, can you move the clutch arm freely & can you feel the clutch bearing when it reases the fingers of the clutch?
The clutch pedal should have a small amount of free travel, then the bearing should press the fingers foward allowing the clutch to disengage, but there MUST be some free travel to ensure that the clutch relesas bearing is away from the fingers to ensure that the clutch has fully engaged.

If the adjustments are correct, then I would suggest that the following are possible.
Lining worn, or torn completely from clutch disc
Center torn from the clutch disc.
Damaged gearbox, ie, striped constant mesh [or primary drive to the cluster]

Make sure that you have free movement of the clutch arm at the gearbox, then connect the cable & ensure that adjustment is correct before dismantling anything.

If the gearbox is actually out already, then pop the clutch off to ensure that the disc is serviceable, & that it is the right one for the gearbox spiggot shaft.

Quote:
Looks like the fork at the top has longer stroke and requires either a shorter cable or has different mounting set up. Maybe check that too.

Yeah im positive. I clearly remember having to strip down my sunny sedan to get the flywheel off as the A15 flywheel i supplied the shop was stuffed, the ring gear was ripped to shreads so they needed another donor.
I mite go have another crack in the shed as how can changing cars it suddenly not work
The only other thing is that is there a difference in the 56a boxes throughout the years? Do they differ at all in the fork/release bearing as they got more modern etc.?

Dave

Are you sure your sunny ran an A12 flywheel?
Reason I ask is a mate had similar problems when he put his together, was a few years ago now! Seem to remember some problem with too much clutch cable length and it was the stock cable........worked it out to be the wrong A series flywheel was bolted up.
Unfortunately this was a long time ago and I could be wrong.
Dont know about the sunny clutch cable being different length. Dodgeman would probably be able to tell you.

There is a bit of room to space the pivot ball out if necessary but it usually isnt needed. I had to do this after fitting a button clutch with lots of other mods.

But the thing is is that in my sunny i was running a 56a series box behind my A15 with no troubles at all (same engine setup and all). The flywheels lightened and same with the clutch setup...

Im using the sunny clutch cable to as the ball ended type for the 1200 was fraed to sh*t so that wouldnt make a difference would it?

Dave

Maybe you have to use a different A series flywheel !!

Im racking my brain as what seems to be the cause of my problem and i cant think of anything more!

Ok so im running an A15 engine with a A12 flywheel with an A14/15 clutch & pressure plate. The Gearbox i am using is a 56a series out of i think an early model 120y (dont quote me on that).

What isnt happening is that the clutch just isnt engaging, if narrowed the problem to not enough throw in the release bearing but how do i resolve this problem? should i use a smaller bearing and another fork from say a 60a series box?





Bearing on the left (shorter one) is off a 60a box, the right is the one ive attempted to use its out of the 56a box




Fork on the left is off the 60a box (notice the different hook) and the right is the 56a fork.

So how do i get my clutch to engage people?! Can you adjust that ball ended thing that attaches to the fork? the 'withdrawal lever ball pin' ?

I cant go any further with my car until this is figured out

Cheers guys
Dave