Hi guys,
i have this PPG 5sp dogbox installed on my b18c honda. Have a good condition low mileage Exedy twin disc(roughly 4k miles), new release bearing, new pilot bearing, braided single piece clutch line, 1yr old slave and master cylinder (that i apparently bought new back then), stock shift linkage with new OEM bushings, engine/tranny solid mounts. now i get a hard clunk and i do mean hard when i try to put 1st gear and thats with the clutch pedal fully pressed. i even get bad grinds when i put reverse. it feels like the clutch is not getting fully disengaged.....tried bleeding the clutch line many times and with no success......Did anyone go through this before? im starting to look into extended clutch pushrods ......is there such thing for a S80/S4C hydro type gearbox?

let me hear your opinions

 

A twin disc typically requires a shorter stroke master cylinder compared to a conventional single disc. Unless your pedal has been adjusted way down close to the floor, I suspect you are actually over stroking the clutch and causing further issues potentially.

Just as a test, push the clutch pedal down HALF the distance to the floor and try to put the trans in gear. If this feels easier, and/or is less noisy... then this is your issue. You will need to install a pedal stop and set the travel per Exedy's instructions.

 

clutch pedal half way is a bit frightening, but i'll give it a shot

the clutch master cylinder is a stock OEM (not aftermarket), which i bought new 1yr back. i dont recall any sort of adjustment under the steering column area where the clutch pedal travel can be adjusted! maybe someone can enlighten me on this one

did i mention if i double clutch on stop and put 1st gear the engagement is much smoother and clunk sounds more of a normal dogbox clunk? well thats where i got the idea my slave cylinder is not disengaging the clutch fully....maybe im wrong?

 

Half way is a guide... with the engine running, slowly depress the clutch pedal and gently apply light pressure on the shifter toward first gear... if it doesn't go it, continue to slowly depress the clutch pedal. At the point that the shifter goes into 1st smoothly, that will be about where the pedal needs to stop each time you push the clutch pedal in.

Remember that a twin disc requires a short stroke to dis-engage the clutch cover diaphragm. Your stock clutch requires a longer travel for full dis-engagement and that is what the stock clutch master cylinder is made for.