Clutch problems again..

[91GSL-SE]

So I have a 91 that has a freshly rebuilt motor (S5 NA) and a trans and driveline out of a 88 vert. It has a new slave cylander, good working master, slightly worn clutch disc and pressure plate, new pilot and throwout bearings. The first problem I ran into was that the clutch release fork had slipped off its pivot point on the transmission in the bell housing. It would go into gear just fine, but when I let off the clutch the car would hardly move. After fixing that problem I let off the clutch pedal and no movement what so ever.

I have plenty of movement in the clutch at the slave and fork, the car goes into all gears just fine, no excessive noise, all new or good working parts.

I'm stumped. Hopin for some help here guys.

Thanks in advance, Rob.:icon_tup:

[bryant]

do you smell clutch any?
are you sure its full of fluid? lol just in case
if not sounds like trans or bent fork?

[91GSL-SE]

do you smell clutch any?
are you sure its full of fluid? lol just in case
if not sounds like trans or bent fork?

Clutch has about 2000 miles on it. Fairly new. No clutch smell. Plenty of fresh fluid. Bled the system. The fork has been replaced. Trans was just working in the vert I pulled it from.

[NoDOHC]

Does the clutch pedal feel spongy?
It sounds like the throwout bearing is getting hung up at the end of the stroke. Either that or the springs are all fatigued, either by heat or by age.
Either way, the clutch should feel spongy.

If it doesn't feel spongy, it is possible that it is improperly adjusted and is never releasing (if the master cylinder never goes back in far enough, the slave cylinder will never fully allow the clutch to engage).

[RETed]

Clutch disc installed backwards.


-Ted

[TitaniumTT]

Ted, it's been a while since I had a stock clutch and I'm trying to remember what it looks like, but I think it would never fully disengage. Or is it a function of the disc splines not making contact with the input shaft splines?

I was thinking what NoDOHC was thinking, the clutch isn't fully engaging due to improper adjustment

[91GSL-SE]

Does the clutch pedal feel spongy?
It sounds like the throwout bearing is getting hung up at the end of the stroke. Either that or the springs are all fatigued, either by heat or by age.
Either way, the clutch should feel spongy.

If it doesn't feel spongy, it is possible that it is improperly adjusted and is never releasing (if the master cylinder never goes back in far enough, the slave cylinder will never fully allow the clutch to engage).

I have adjusted the clutch to engage fully.
No spongy feeling at all.

[91GSL-SE]

Clutch disc installed backwards.


-Ted

Nope double checked that.

[RETed]

Ted, it's been a while since I had a stock clutch and I'm trying to remember what it looks like, but I think it would never fully disengage. Or is it a function of the disc splines not making contact with the input shaft splines?

Even though the OP says this is not the case, I'd figured I'd answer this anyways...

If you look at the clutch disc hub, it's not symmetrical on the "snout".
The hub that faces the flywheel is shorter.
If you install the clutch disc the wrong way, this hub will ride on the eshaft, causing the clutch disc to never engage and mate with the flywheel (mating surface).
You can bolt everything in and not notice anything, cause the pressure plate will just push back on the spring fingers.
The only way you can inspect this is you'd notice the clutch disc face is not resting on the flywheel when looking through one of the "inspection holes" in the pressure plate cover.

Result?
The clutch will never engage, but everything (clutch hydraulics, fork, etc.) will work just fine.


-Ted