Forum:
Hey Drivers,
Here is my problem for today.
Daihatsu Fourtrak F73 (1998, SWB, 2.8TD)
I had it at the garage for a clucth change and transmission check up.
(clutch felt worn, transmission/transfer had various noises, rattles..., was getting burnt oil smell from the transfer, or so it seemed, was disengaging first gear on downslope, etc...).
Mechanic did very poor job. Gave me the car back twice, twice something failed and had to take it back.
So changed: Clucth Plate (OEM) Disc (OEM) Shaft Bearing (?), and had flywheel rectified.
Changed whole set of transmission/transfer bearings... (about 
Eventually changed clutch cable with one from a completely different make/model vehicle (I don't know what vehicle it comes from. It is adjustable with a nut/wrench instead of the E-Ring the old cable has) (Shaft bearing was taken from another vehicle also ..... Toyota 2L engine transmission if not mistaken...)
Got it out of the mechanic shop (They were not doing good job at all).
Now feels like there is a clutch slip (Revs go way up before acceleration responds when reaching 2000/2500 RPM)
Gears are hard to engage (randomly)
Don't get full torque of the gears (feels like a small smooth car gear/ratio/compression rather than the torque full fourtrak)
Reverse will not engage without lots of grinding...
Wondering if it's all due to an incompatible/improper clutch cable....or can the problem be more serious...(Hope not)
Don't know what else to mention....
Hope someone can give me an idea with those details I exposed.
Thanks in advance to anybody who takes on their time to help me out...
And...
I forgot to mention that clutch pedal doesn't press all the way down ... it only goes down about half the travel I had experienced before the "repair" and I cannot tell "free play" from "clutch play". It's a mess.
Your addition sounds like the
Your addition sounds like the cable, which was never likely to work as its from a different vehicle. As for the rest, it could be anything if he has had the box apart, what made you go for a repair? Buying a second hand box would have been a good option, if they spent as much time and money as it sounds like "fixing" your current one. Looking at your symptoms again, they could be that the clutch cable is to short, so the clutch is never fully engaged. Do you smell anything after you've driven?
Transmission Problems
I had the box repaired because of different things. It was disengaging 1st gear when going down hill (when using gear braking). I was getting this burnt oil smell that seemed to come from the box (typical gear oil smell) and when I checked the transfer oil level, it was wayyy over filled as about half a gallon of oil spilled from it before it reached the normal "level". Figured transmission was leaking oil into transfer. They found many worn bearings in the box. Didn't think of getting a second hand one and would have been nearly impossible in this part of the world.
As for the clutch, it had very little "clutch play", had a very loud rattle when depressed (figured it was clutch fork)....
I am not very skilled mechanically wise...but I needed to do lot of travel lately and figured I would prevent rather than heal.
So now, these symptoms....
I am not getting any burnt clutch smell (which kind of has me puzzled), but I do recognize symptoms of clutch slip, loss of power, high revs, grinding gears (especially reverse and 5th)....
Will replace cable with OEM one to start with.
I am so upset with these mechanics.......they are supposed to know their job but no.....
So there it is....