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My brother and I are having some difficulty spliting the engine from the gearbox on his half cut. We undone all the 4 nuts/bolts around the belhousing and all the other engine lines brackets / exhaust, etc however it still doesn't want to come completely free. We have got a gap around 5-10mm between the two but it doesn't want to go any further. Any suggestion of what it could be? Could it somehow be the clutch fork stuck? We are open to suggestions... It has to be something silly so bring on the stupid thing we have forgotten..

Thanks
Matt

ej20h???

im hoping your trying to bring it out straight instead of up and out of the engine bay.
check for dowels

Is the engine definitely clear of the engine crossmember?

Also, put a jack under the front of the transmission (pretty much under the hump of the front diff) and jack it up to just before the point were it just starts to lift the engine, to take the weight off the dowels

Yeah trying to bring in forward, dowels are clear enough. Also other details is it is a 4 bolt (Yes a 4 bolt not 8 bolt, triple checked this) and has a hydralic clutch.

Thanks Suparoo the weight is off the gearbox. And engine mounts are clear.

if the engine is to come off the gbox theres the 4 bolts and remove the starter motor and in behind the starter there is a 10 mm allen key take this plug out and there will be a thread in side(6x1.25 i think)i grab one of the big bolts out of the front plastic cam covers and screw it in then lever off the box and it will pull a big pin out...
The pin is the pivot for the clutch leaver(pull clutch)....youll get wot i mean.
oh and lift the fork up and release it from the clutch.....
have fun....suby

What ohsuby said is right if it is a turbo engine. Non-turbo will mean it is some thing else. To me it sounds like the input shaft is frozen to the spigot bearing, even with a turbo engine you can get them further than that apart before the TOB gives you grief. If it is the spigot, the only way you will get it out will be with force.

i agree - gotta be the spigot stuck (it's happened to me). force is the only solution

Thanks guys it is a pull type clutch, i will pull that pin out tomorrow and go from there. I had already removed the cover and had a look at that and thought that could be a posibility. Also it would surprise me about the spigot... I will pull the fork out and then give it a good old pull forward.

Outback bloke it is Twin Turbo.

Also what is the chances of actually damaging anything on the fork while we have been trying to pull it apart?

that was my first thought the clutch fork and associated spigot is stuck in place

its pretty hard to damage that stuff you would have to do it intentionally with lots of force

TOONGA

ohsuby wrote: in behind the starter there is a 10 mm allen key take this plug out and there will be a thread in side(6x1.25 i think)i grab one of the big bolts out of the front plastic cam covers and screw it in then lever off the box and it will pull a big pin out...
The pin is the pivot for the clutch leaver(pull clutch)....youll get wot i mean.
oh and lift the fork up and release it from the clutch.....
have fun....suby

this is definitely the problem. It's a common thing that gets heaps of people stuck when they havn't done a suby pull clutch setup before. Lots of people force the gearbox off and smash the thrust bearing to pieces potentially damaging the pressure plate. Just take the big pin out using the method above and it will all just fall apart

happened to me once on gen3 liberty, could not seperate the gearbox, don't know why it was locked tight, but used tree (hard plastic) wedges in 3 points (one top & 2 bottom left and right of the gearbox and use a hammer in equal force in 3 points and it got seperated.
Cheers
AP