major clutch problem

[jdombrow]

alright. Im baffled. I have no idea what it could be anymore. I put a brand new act 2900 in with a 6 puck unsprung disk new pivot ball and fork along with oem tob

for the breakin I did around 300 miles stop and go in town, along with a 250 mile round trip mainly highway.

at around 250 miles my clutch was solid. engagement halfway off of the floor. the next day engagement was on the floor. I had to press down extra hard against the floor to get it to fully disengage. 1/2 inch up and it was fully engaged.

I assumed I had a leak, went through and bled the clutch with a full 8 oz bottle, using a hose on the bleeder into a bottle 1/2 full of brake fluid to no suck any air back in.

after bleeding engagement was the same, just off of the floor, then I drove the car 250 miles like that with only a few shifts and having to really push to get it to disengage.

the next day I went to work, then did 3rd gear pull for logging purposes, had trouble getting out of gear, thentrying to upshift 3-5 I couldn't get in. stopped the car and wasnt able to get the clutch to disengage while sitting with pedal to the floor. ended up putting car in second and starting it, clutch was slipping at startup and I slowly creeped forward having to give it gas to keep idling like that for a few seconds. drove the car home like that, no slippage or anything engaged solid barely off the floor.

I started it last night with my foot to the floor again and It started but wanted to pull ahead a littleand was definately slipping.

so I checked the obvious, slave looked like It was pushing well enough. but my pedals always been verry soft, so I re-bled another bottle through making sure to bleed the slave to after installing a new master clutch cylinder. now engagement is solid with pedal at the floor, the forks moving all the way and not hitting the housing or anything, but there was still a little room, so I put in a extended slave cylinder rod the +1/4 inch one and that makes the slave push the fork until its just about touching in the housing. started car and it lurched forward.

slave rod all the way out and clutch is still fully engaged. I already adjusted the pedal.

trans has a brand new act 2900 with 6 puck unsprung disk, new oem tob, new pivot ball and new clutch fork. and I did not shim the pivot ball.

any suggestions? shim pivot ball? could fork be bent? is there anything I can do to check anything without removing the trans? bad pressure plate?

please help. Im completely lost right now.

 

[Dallas J]

Inconsistent pedal is usually loose transmission bolts. Make sure you have the rear bolt in, the one the goes in from the driver side right above the T-case.

I had a very similar problem and this along with proper adjustment fixed it. I adjusted the clutch pedal by tightening it to just the point where I could no longer push the slave cyl in by hand. Then backed it off 1/2 turn and double checked that I could push it in. If you cant push it then youll get that pedal pump-up so common with out cars.