I just had the clutch replaced in my 98 ex.

First thing I noticed is that the engagement either grabs or doesn’t, if that makes sense. I’m used to being able to “ride the clutch” a bit to get the car rolling smoothly, but now it just catches so it’s a little harder to engage smoothly.

Is that how a new clutch acts until it’s been driven a while? Never had a “new” clutch

Also before the new clutch the pedal play was about 1/2”. Now it seems the mechanic adjusted it so there’s a good 2” of free play before the rod actually starts pushing on the master cylinder.

I tried adjusting it back to 1/2” but it makes the engagement way at the top.

Is this normal for a new clutch to increase free play so the engagement is about half way of pedal travel?

 

The hydraulic clutch it should be kinda half way yes. Between halfway and three quarter is full engagement typically. The initial engagement is a lot closer to the floor but you might not notice it initially, especially during the break in period.

With a brand new clutch you are supposed to be gentle with rpm and slow steady release for roughly 1000 KM or so. This allows the clutch disc, flywheel and pressure plate to marry to each other without creating hot spots and significant glazing. Then after that you can pop the clutch, do higher rpm engagements etc.

I believe it's supposed to be about 1" free play before rod pressure but I could be off. It's been awhile since I checked that part of the manual.

 

Does the free play need to be re-adjusted after the break in period? Because right now free play is maxed out to allow it to engage about 1/2 pedal travel. It disengages/engages with what feels like about an inch of actual rod pressure.

Btw it’s not an OEM original clutch that was installed if that matters?

 

I've never adjusted the pedal free play. I have always been able to leave it at factory setting.

An aftermarket pressure plate could potentially act differently than stock. The pressure fingers could have different angling etc causing different engagement and disengagement positions etc.

This is how the pedal adjustment should be done: