So this car is getting on my last nerve. I install the new Exedy Clutch setup and as Im about to reverse the car out of my driveway to go get the tranny mount bracket welded, I get no gears.

After double and triple checking things and installing a new master, slave and other stuff. I pull the tranny in the gorgeous NYC november chilly night. I verify that the clutch disk is installed correctly with the thick top hat portion facing the pressure plate and release bearing, and the flat side is fitted flush against flywheel. I don't see anything out of the ordinary, but when I test fit the new Exedy disk on the input shaft, it slides on with a little persuation but it is hard as *** to move back and forth on the shaft. In fact I had a hard time getting it off the input shaft. I try the old disk and sure enough the old disk can glide back and forth on the input shaft.

I dont have much knowledge about the clutch engaging and disengaging, But I assume this is the root cause of my problem. Can anyone confirm this theory before I get a new setup tomorrow AM and install everything to attempt to drive the car?

I assume when the clutch pedal is pressed, the pressure plate release tension on the clutch so it separates from flywheel. My theory is that the current clutched was wedged up on the input shaft against the flywheel., so whether the pedal is pressed or not, the clutch disk doesnt move -- hence not allowing gear shifts.

Any information you can share would be greatly appreciated.

Help get this car off this flatbed

 

That's your problem. The friction disc MUST be able to slide freely on the input shaft. (You did put a little hi-temp lube on the shaft as well, I hope?)

I don't know what your Exedy clutch looks like, but if you study the OE plate, you'll see a sort of wavy metal spring between the faces of the friction disc.
- When your foot is OFF the clutch pedal, the pressure plate squeezes the friction disc against the flywheel, and that wavy spring is compressed flat.
- When you push the clutch pedal--pulling the pressure plate away from the friction disc--the wavy spring suddenly pops open again, and this action causes the friction disc to jump away from the flywheel.
- If the friction disc is sticking on the splines of the input shaft, it will never be able to jump away from the flywheel, and the effect will be exactly as though your foot was OFF the clutch pedal.

 

I did use decent lithium grease on the shaft. but the splines are so tight, it doesnt even leave room for lube. I'm going to exchange the disk in a few minutes and try another one and/or get one that actually moves freely on the shaft.


thanks!

 

make sure the splines are not twisted or anything abnormal, i know this is a dumb question but do you remember if the edged of the clutch disks hub chamfered like where it goes onto the input shaft.

I know exedys not cheap, but i remember hearing about people getting axles stuck in older obx lsd's, they didnt have a chamfered edge machined into a part making it hard to move, and axle splines and the input shaft are similar so just a thought.

of course input shaft doesnt have c clips which is the problem there

 

how did your throwout bearing move? smooth or did it also have some binding problems?

 

I'm thinking your throwout bearing/shaft. But how the clutch was hard to move up and down the shaft by hand makes me think it could very likely just be the clutch.

 

id say prob the input shaft or the tranny case where the throwout bearing rest, dont know too many exedy clutches that come defective, tho it does happen and it also may have been damaged, id say just crack that bish open and get a look at what you can see

 

Also FYI... it is a RhinoPac clutch from Parts Authority, but it actually has a stamped Exedy disk. (Go figure)

I do not believe the disk splines were chamfered. I already packed it back in the box to return for a refund (But I will snap pics in the AM)

Well I tried the new Exedy (RhinoPac) Clutch Disk on a second B-Series tranny in the shop. and the same results -- Disk can not easily be seated on spline without significant force. The disk can not easily slide on the shaft if at all. The release bearing movement and fitment with clutch fork were on point. No abnormal behavior and well lubed.

I ended up putting my old clutch disk and PP back on for the sake of getting the car back on the road. and sure enough that particular disk moved with ease on both my tranny and the spare shop B-tranny.

I got everything together and the car now can engage the gears. I am still very confused as I have never ever come across this problem in owning manual tranny cars since 1997.

 

There is only one possible reason for this problem: Your aftermarket parts were badly made.

 

Sounds like you figured it out! sounds like POS clutch disk problem! hope all works out

 

Yeah man, I had a cracked tranny housing that I needed to swap, and I figured since the tranny was down, I'd throw in new clutch. We'll it made the job twice as long. and aggrevated the crap outta me! I just gotta weld up the new Tranny mount frame bracket today and I should be 100%. Maybe I will attempt to do a header install if I feel brave and the weather cooperates.

Thanks for all the input!

 

Why are going to weld your rear mount? why don't you just get an aftermarket hard rubber one?

 

^^ I just saw this.... It wasnt the rear mount, it was the pass side mount that broke off the frame rail. I have since bought the OEM mount from Honda and had that old mount cut and ground off, and the new mount welded in place. Tranny is up with OEM clutch disk and all has been running great for the new year. I have about 1600 commuter miles on the new setup already and seems to be working great.