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Some clutch issue Questions.

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river

15+ Year Contributor
282
0
Jun 9, 2004
Anchorage, Alaska
ok, my main question here is about shimming the pivot ball, but i will get there in time.

i have a 91 GSX, shepard tranny, ACT 2600 pressure plate/street disc, SS clutch line, and thats it as far as the drivetrain in relation to my post right now.

my car had been having issues with going into gear properly, so initially i figured it was an adjustment problem. i adjusted the clutch and the car was fine for a few days, then one day it got bad again. so i read up on it and figured the next easiest/cheapest thing to do was to pull out the clutch pedal assembly and have it welded, sure enough...TONS of play in that thing. put it back in the car all welded up and adjusted it again and that took care of the problem, or so i thought. i drove the car for a few weeks and it was great, no problems. then, one day going to work i took the car out of gear at a stop light and when i tried to go back in to gear it wouldnt go in easily. i depressed the clutch hard and tried to put it in gear and it wanted to start moving the car as i was trying to push it into gear, as if it was starting to disengage the clutch...but not fully. so i tried starting it in gear with the clutch depressed and it wanted to move the car foreward with every rotation of the motor. called the tow truck and had it taken to the shop.

now, the fun begins. we take the tranny out only to find a completely shredded ACT TOB, cheap plastic. we put in a good Mitsu OEM steel TOB thinking that was the problem, put it all back together, bled it and readjusted it....same thing. clutch not fully disengaging. so, we take it back apart to check the disc again and make sure its just not burned down too much, surface the flywheel and buy a new disc because the old one was out of check. put it back together, still the same thing, clutch not fully disengaging when depressed. time for a new master and slave cylinder, no luck. so now i am at the point of putting in a new clutch fork and pivot ball, we will see what happens. what else beyond all of this could be a/the problem?

what i am wondering is, if i put in a new pivot ball, and a new clutch fork, is it suggested that i still shim the new pivot ball? i thought that the reason for shimming would be old worn parts, but i may be wrong. the point im at is, putting the pivot ball and new fork in, and if that still doesnt fix it...go on to the longer slave rod and see if that helps. but is there a better principal behind one or the other, should i just shim the new ball, or leave the new ball alone and try it, then if no avail...go to a longer slave rod and if the rod doesnt work, then shim the ball and use the longer rod? where would you guys go in this situation?
 
river said:
does nobody have a suggestion for me, no wisemen advice or anything??? c'mon...give me something.

You welded the nut on the end of the clutch pedal assembly and you know you have absolutely no free play in the clutch lever, rod, pedal arm, or clevis pin, and that the master cylinder rod is being fully depressed into the master cylinder?
When I did my temp weld on the clutch assem. ped, I wasn't aware that the square hole in the clutch lever that the rod goes through was stripped just enough that I wasn't getting total disengagement. When the clutch pedal was fully disengaged I could still pull it back with my hand about and inch to and inch and a half. I fryed my clutch...
After installing a new flywheel surface, disc, clutch, TOB, clutch fork, fulcrum (pivot ball), master/slave cylinder, I had to replace the clutch assembly pedal and now I have clutch.
Let me know...
 
Greg Collier said:
You welded the nut on the end of the clutch pedal assembly and you know you have absolutely no free play in the clutch lever, rod, pedal arm, or clevis pin, and that the master cylinder rod is being fully depressed into the master cylinder?
When I did my temp weld on the clutch assem. ped, I wasn't aware that the square hole in the clutch lever that the rod goes through was stripped just enough that I wasn't getting total disengagement. When the clutch pedal was fully disengaged I could still pull it back with my hand about and inch to and inch and a half. I fryed my clutch...
After installing a new flywheel surface, disc, clutch, TOB, clutch fork, fulcrum (pivot ball), master/slave cylinder, I had to replace the clutch assembly pedal and now I have clutch.
Let me know...

i know that when i pulled the clutch pedal assy. out that it was not that badly worn to begin with. i only got about 1/4" of free play out of the pedal, so i made sure the placement of the arm was correct, and welded the nut to the washer and then also onto the arm itself. i know that none of that area has any play in it after i welded it. the only place it could have any play is in the area where it has that little plastic bushing and that wasnt even that bad, so i put it (plastic bushing) back in place. after i put the assembly back in the car, i cant pull the clutch arm up any more after it is released. that area seems to be ok, it could be the culprit, but at this point i know i had more than one thing wrong in my whole clutch system. i guess that if i do end up needing a whole new pedal assembly, it wouldnt be the end of the world...doing the whole swap procedure again would be much quicker the second time around.

besides the point, that wasnt mainly what i was wanting to know. i mainly want to know if i should shim the new pivot ball right from the start, or if shimming a new pivot ball isnt a good idea. also, i if i should shim the new pivot ball, then if that doesnt work, also do the extended rod.
 
I am having similar problems, and the pivot ball is a good ?. I have the ACT 2600 w/ streetlight flywheel. I was having problems, so I put in the extension rod, and adjusted out as far as I could the rod underneath the dash, but that is as far as I went. I hear about welding a nut to the master cylinder rod or something, but I don't really understand what is being done here. I was going to try that next, but I counldn't get anyone to explain to me what to do, then if that didn't work I was going to shim the ball. Just thought I would put in my .02 cents.
 
The concept of shimming and or welding in this case is usually to assist in the movement of warn out parts. When welding a nut at the end of the m/cylinder rod you're adding more adjustment to rod thereby compensating for a warnout clutch pedal assembly. In my case I installed an entire clutch system including a new clutch fork and fulcrum (pivot ball). Having already installed a new m/cylinder and extending the rod to its maximum it still wasn't enough to fully disengage the clutch. The only thing left to change was my clutch pedal assembly and once I did that I had clutch...
You need to know that both your master and slave cylinder rods are fully extending when you push the clutch in. And then there's the obvious, have you bled the system? If there's any air in the clutch system you'll end up with the same negative results.
 
Greg Collier said:
The concept of shimming and or welding in this case is usually to assist in the movement of warn out parts. When welding a nut at the end of the m/cylinder rod you're adding more adjustment to rod thereby compensating for a warnout clutch pedal assembly. In my case I installed an entire clutch system including a new clutch fork and fulcrum (pivot ball). Having already installed a new m/cylinder and extending the rod to its maximum it still wasn't enough to fully disengage the clutch. The only thing left to change was my clutch pedal assembly and once I did that I had clutch...
You need to know that both your master and slave cylinder rods are fully extending when you push the clutch in. And then there's the obvious, have you bled the system? If there's any air in the clutch system you'll end up with the same negative results.

Thanks for the info. Can you tell me where is the cheapest place to get a whole new assembly? Also, do you think this could be causing my car to stall when I push the clutch in and come to a stop?
 
Just get the assembly from a Mitsubishi dealer. They aren't that expensive. I just bought the new clutch pedal, lever arm, and all the bushings (for the brake pedal too, I thought I may as well replace those too while I am in there) from the dealer. I think the pedal was like $45 or so, I can check later tonight if you want to know for sure.
 
turbotsi92 said:
Thanks for the info. Can you tell me where is the cheapest place to get a whole new assembly? Also, do you think this could be causing my car to stall when I push the clutch in and come to a stop?

I got mine from DSMotorsport, if I remember they're charging like $75.00. If the dealer was only $45.00 Holy Cow what a rip :nono:

If your clutch is not completely disengaging then the flywheel is still pushing against the disc, pressure plate, tranny spline, thus it's like being in gear and putting the brakes on. Yes your motor will stall OMG
 
Yes, I am pretty sure the clutch pedal assembly only cost me about $45. The lever arm and bushings were another $40 or so. I am at work right now, so I can't look at my receipt, but I am doing a write-up on the whole pedal assembly rebuild for another thread, and planned on posting all the parts I used and approximate cost from the dealer in that thread.
 
DarthBulk said:
Yes, I am pretty sure the clutch pedal assembly only cost me about $45. The lever arm and bushings were another $40 or so. I am at work right now, so I can't look at my receipt, but I am doing a write-up on the whole pedal assembly rebuild for another thread, and planned on posting all the parts I used and approximate cost from the dealer in that thread.


Oh... OK, I was starting to get a little pissed :shhh: I got the complete assembly set pedal/rod, lever, and bushings, so the price was about the same give or take 10 bucks. Now I can sleep at night :cool:
 
OK, I looked at my receipts! The parts and prices from the dealer were as follows, for me:

MB599233 Clutch Pedal - 35.08
MB012212 Clutch Return Spring - 3.43
MB534210 Bushing - 3.68 (2)
MB534211 Bushing - 5.72
MB058634 Bushing - 2.08
MB599879 Lever Assembly - 21.85

Total Price - 75.52

The bushings for the brake pedal are included in the above list. I just noticed that I forgot to order one bushing...the little one that goes in the lever arm, where the clutch master cylinder clevis attaches to it. Oh well, off to the dealer again...
 
ok, so what fixed my issue was; a new pivot ball (shimmed a few milimeters), extended slave cylinder rod, and a new clutch fork. after all that, plus the previous parts (new TOB, new disc, new slave/master cylinders, and a welded clutch pedal assy.) the issue is fixed. if it goes downhill again, i will know its time to do some rebuilding of the clutch assembly because its the ONLY possible place left that there could be some wear and tear.
 
river said:
ok, so what fixed my issue was; a new pivot ball (shimmed a few milimeters), extended slave cylinder rod, and a new clutch fork. after all that, plus the previous parts (new TOB, new disc, new slave/master cylinders, and a welded clutch pedal assy.) the issue is fixed. if it goes downhill again, i will know its time to do some rebuilding of the clutch assembly because its the ONLY possible place left that there could be some wear and tear.


Did you try everything in this setup MINUS the extended slave cylinder rod?

I heard it puts constant pressure on TOB, and is only a band-aid. I wanna know because I have a similar problem with ALL new parts.
 
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