Hi everyone, I have recently installed a pinto into my mk2 esky 1.6gl. I have taken the engine and box from my panelvan and put into my 4door complete. So the box and motor have never been apart. However I just hooked up the clutch cable which is the onefrom the 1600. Now the clutch wont disengage. Is there a difference in the 2lt cable vs the 1600 cable. Anything ive missed?

Hi Mitchy, a 1600 cable is much shorter than a 2lt cable. Is the cable under constant tension even when no pressure is on the pedal?
 
Rhys

When I first hooked it up it pulled the pedal to the floor but I adjusted it at the lock nut and the pedal has come out but the clutch only just disengages when the pedal is hard on the floor and I lift it 2cm off the floor in gear and it takes off?

Hate to tell you this Mitch but you are going to have to pul out the gearbox. I had the same problem the first time I did the same conversion. There needs to be a spacer under the pivot point where the clutch release fork bolts to the bell housing, from memory I think it need to be 5mm thick but I would check with a 2 l owner for that (it was a long time ago when I did this). Once I put the spacer in problem solved.

Its the complete box an motor from a 2lt though? I pulled it out together and slid into my other car so clutch everything is from a 2lt already? Do you have any pics of the spacer and where it goes ? If you do can you email them to me, mitch.carrington87@gmail.com

Didnt want to have to pull the box out :(

I misread your first post, if they were working together before the only suggestions I have would be as per Rhys. I've seen collapsed release forks but as a first step I would double check the clutch cable is adjusted properly (sorry if I'm telling you how to suck eggs).

Just double checking, the panel van isn't a car you bought for parts, I mean, you have actually seen the clutch operating properly in it?

You should only need the spacer if the box was off the back of a 1600 motor. It goes under the point where the clutch release fork bolts to the bell housing.

I originally bought the van for the engine an diff because I was told it was full of rust for $200 and after stripping it back its nearly rust free so doing it up next. Its a matching number car so im assuming the box is a 2lt one however the clutch did the same thing in the panelvan it never worked. The owner said it had snapped but it hasn't. Unless its something inside the box, this is my first project car and first real mechanical work which doesnt help lol. Ill have a olay today and try swap the cables over

Mitchy if cable is the issue it will be at full adjustment one way or another yours is with locknuts to the cable housing end? rather than to the end of the thread end if that makes sense. Moving the locknut towards end of thread end tightens up any slack in system and bring pedal further of floor in its 'relaxed state' but it sounds like your issue is too much tension so if you have it fully backed off and still no good then try the 2lt or a TC onwards 2lt Cortina cable.
 
Another option is you can pull cable out of the bellhousing locating hole slip a spacer on the threaded section of cableand feed back through, this essentially moves the pivot point back by the distance of your spacer which may be enough to get the pedal travel you require.
 
Rhys
 
 

Thanks guys ill give that a go to, fingers crossed the box can stay in appreciate the help