the engine is a 89' d16a6. using stock 89 flywheel. i bought an exedy clutch kit(stock replacement). i tourqued the flywheel bolts and pressure plate bolts to spec, new throw out bearing as well. heres the problem:
if i adjust the clutch so it grabs at the top off the pedal i can push it in about 3-4 inches and it will go into gear anything past that it acts as if the clutch pedal is not depressed and i cant put it in gear. no matter how i adjust the clutch it only has a few inches. right now its adjusted so if i put it to the floor i can shift but the freeplay is several inches. i figured i'd drive it around and see if it brakes in and now it chaters a good amount when letting it out slowly, and no change in clutch pedal travel after 75 miles. sorry for the long post but i really dont want to tear it all apart, i just got done putting the motor together and it has to go for smog by the end of the month. thanx in advance
*edit* and it doesnt grab for ****, it doesnt slip, just not grab like an new clutch.
*could it be possible that the pressure plate teeth are being pressed into the dlutch?i dont here any noise when it does.

Ehren


Modified by dcvt16 at 3:22 AM 5/18/2004

 

bump!

 

please help!

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by dcvt16 &raquo;</TD></TR><TR><TD CLASS="quote">please help!</TD></TR></TABLE>

 

did you resurface the flywheel? if not, then that might be the problem for the chattering. it might also be a torn mount.
to adjust the clutch engagement, there is a **** on the clutch cable. it looks like a cap and has a ball at the end. turn the cap to adjust the clutch freeplay. it would probably be easier to adjust if you have a friend help you. if it doesnt go in, then you need to either turn it up or down. theres only one spot where its supposed to be. if you go too low then you wont be able to put the car in gear when the pedal is all the way down. if its too high then you wont be able to put it in gear at all. i cant remeber for sure but it might be the other way around but you get the idea. easiest to do if you pull the ebrake and let the clutch out slowly until its at the spot you feel comfortable with.

 

if i adjust the clutch so it grabs at the top off the pedal i can push it in about 3-4 inches and it will go into gear anything past that it acts as if the clutch pedal is not depressed and i cant put it in gear. no matter how i adjust the clutch it only has a few inches. right now its adjusted so if i put it to the floor i can shift but the freeplay is several inches.

ive had the adjustment all the way loose to all the way tight and everywhere in between with the same result, but just at different travel points in the clutch pedals range of motion.

 

hmm thats odd. keep messign witht he adjustment. are u sure you put in the throw out bearing correctly? the clutch should slip a bit until its broken inafter 500 miles.

 

when you say freeplay, do you mean that the clutch pedal just kinda hangs and doesnt kick back? my clutchmasters stage III did that after i installed it. i am thinking that the clutch cable is loose but i didnt mind.

 

no it kicks back to the top just no cluch for most the travel.

 

bump since i'm having a similar problem with my clutch...

 

well, i just drove about 150 more miles and the clutch started working a whole lot better. im going to re udjust and see how it goes.