I just DIY installed a new Exedy OEM clutch and new OEM flywheel in my 99 CR-V.

The install was a mild nightmare. Initially, the clutch was not lined up properly and I did not realize until I had already tried fairly hard to get the engine and transmission to mate by trying to pull it together with bolts. I thought I was being careful not to put too much strain on the bolts, but I guess not -- I got fed up and took the clutch off and noticed that there were nicks on the splines on the clutch disc caused by it not being lined up with the main shaft. I polished the splines until they slid smoothly over the main shaft and reinstalled. After that the transmission mounted very easily.

However, on the first test drive the clutch was slipping badly and chattering violently if I engaged the clutch while decelerating.

Adjusting the pedal did nothing to fix the problem. I have not bled the clutch fluid yet, but the pedal feel is good.

No other unusual noises/feelings.

Any idea what could be causing this problem? Did I warp the disc or diaphragm? Is the transmission going to have to come off again?

I can't waste another three days so this car is probably going to have to go to the mechanic...

 

Mods please move to transmission/drivetrain.

Sorry I posted in the wrong spot -- it was a long day...

 

I can only guess you bent something when you tried to install it it originally while not aligned. Did you not have a clutch alignment tool ?

 

I had one of those cheapo plastic ones. I am not sure what went wrong the first time but the second time I believe it was correctly aligned. The transmission went on very easily.

 

There is a high possibility you bent something by trying to force it. Did you be sure to spray the disc, pressure plate surface, and flywheel surface off with brake cleaner before install? The oil can cause major issues as well. You NEED to bleed the clutch! Also, it shouldn't take more than 6 - 8 hours for a clutch change on a CRV.

 

I did not spray with brake cleaner, although I was aware of the risk of contamination and was careful when handling them. I suppose it would be a bad idea to spray some brake cleaner in through the hole for the clutch fork...

I will try bleeding the hydraulics and update.

I could see someone doing it in 6-8 hr., but me, alone, with my experience, no air tools and and no help, there's no way I could do it in one day.

 

The flywheel, pressure plate and clutch imo should always be sprayed down with brake cleaner to remove the stuff used to prevent rust during shipping/storage.

 

Did you change the throw out bearing?

 

I guess there's a chance if some grease or oil got on the flywheel that that is what's causing the slipping. If so, I would say if you kinda find a safe spot and just work the clutch a bunch of you can atleast test that theory. There's a chance it might burn off after a whole lot of clutch engages/disengages.

 

Theres also the possibilty of the slave cylinder having lost its seal. If you pulled the slave cylinder off of the transmission/clutch without relieving the hydraulic pressure, it could have pushed out and damaged the seal, which could also give you clutch chatter/slipping due to improper clutch disengagment. I would definitely bleed that slave though.

 

Thanks everybody for your responses. It turns out there was no problem with the clutch. I'm not sure how it happened, but the passenger side axle popped loose. I actually double-checked it but missed it both times. So it was the axle slipping and not the clutch. Although the axle was a bit torn up, there was no damage to the differential splines, so a new axle later, and the car is driving fine.

So if anybody else has a similar problem after a clutch install, make sure to carefully check the entire driveline.