Transmission Mystery ... LONG READING

[djgalant]

Ok people. Here is the problem.
The car is 1990 eagle talon AWD tsi turbo.
I bought the ca about 6 months ago , and at the time the transmission did not work.
Friend of mine who is mechanic took out the motor and disconected the transmission from it, and quickly we find out that the throw up bearing was into peces and pressure plate was not in the best condition.
So I ordered ACT 2100 clutch set kit ( new NSK bearing, disc, and pressure plate) and friend of mine installed everything back. The car fired up, and the transmission after it was bleeded
was working fine.
Recently i i seized the motor.
So i got the jdm motor installed, and we installed mine transmission back.
Engines fires up nicely with perfect 150 compression on all cylinders.
I have no tachometer readibg though - due to different plug.

HERE IS THE PROBLEM!
After bleeding the clutch so many times, when car is on, the transmission grindes and doesn't go in the gear.
When car is off, the gears seems ok.
We changed the slave cylinder, put the one of my friend's car, then bleeded about 6 times more with no success, The tranny grides, and doesn't go intgo no gear,
It looked like the pressure plate problem, and my firnd decided to take evrything again apart to see what's up.
After taking the motor and tranny again out, everything looks visually ok.
Disc, pressure plate, fork , t. bearing, evruthing is in the excellent condition.
The transmission itself looks good too. The shafts are working right, the gears are comming in ,and everything.

My friend coudn't believe that this didn't work and called his other buddy who works for dodge dealer as a mechanic to see what's up.
The guy looked at evrything and said that everything looks good to him.
WTF????
Have any1 experienced anything like that before?
Of course when tranny was installed we checked the pressure for master cylinder and checked the cables also.
WTF???
Plese lhelp me here.
IS there anything that i can do to make this work?


The only concern that imay be the problem is the flywheell that came with that jdm motor.

 

[jott5555]

if the jdm motor was from a fwd the awd flywheel has a smaller diamiter than the fwd. just a idea not to sound stupid buy did you refill the tranny with trans fluid? i mean that sounds like the only thing i can think of.

or mabey your pedal needs to be adjusted so it fully enguages and disenguages the clutch. it may not have enough play in it.

just a couple ideas..

 

[Mike1992]

Check out this page http://www.roadraceengineering.com/clutchandflywheeltech.htm To me it sounds like the clutch fork is worn or you need to do some major adjusting of the clutch pedal, so the tranny actually disengages so you can shift. Put the tranny back on the motor, see where the clutch fork is sitting sticking out of the housing.

Clutch Fork Sticking out off Housing

1. { / } Bad - Shim Clutch fork pivot ball with washer or replace fork and pivot ball entirely
2. { I } Good - If not able to get car into gear, adjust the clutch pedal, where it meats the clutch master
3. { \ } Best - Adjust pedal if getting into gear is a problem same as above

 

[realhp=turbo]

STEP!!! This is another problem easily solved. You must make sure that you have you factory flywheel machined to something like 0.61 inches shorter or something. I belive the paperwork that comes with the clutch will tell you what it is supposed to be.

PS All else fails read the directions

 

[x camaro owner]

after you do everything the people before me said maybe this will do the trick

http://www.dsmparts.com/slave_cylinder_extension_rod.htm