New clutch and slipping after 500miles

[ClassicalBor]

So about 3.5 weeks ago i decided it was time to get my clutch replaced. I had 93,000miles on my original clutch, gears were hard to get into sometimes, and reverse grinded half the time, clutch engaged right off the floor...

I did not get anything fantastic as far as aftermarket clutches/flywheels go so i just looked at a replacement. Local garage replaced it with a NAPA part made for my car and flywheel, along with clutch slave cylinder and bled/flushed the system. They commented that the fluid previously in my transmission was Automatic Transmission fluid (probably from the previous owner... i bought this car in August.) and they replaced it with the correct spec Manual tranny fluid specified by the factory.

Obviously i wanted to break in my clutch slowly so i never gave it any excessive gas or anything... until about a week later i got on the highway for the first time and in 4th gear giving it 60-80% throttle i noticed the RPM slip from 3k rpm (@ 65 mph) to 4k rpm quickly then back down to 3.5k rpm and progressed on fine from there.. Similar thing happens in 5th gear and slightly in 3rd. I do not notice it in 1st or 2nd i think because the slip it small and the gears are too quick and overcome it fast enuf. I asked the mechanic to reflush the system in case maybe there were airpockets in the fluid but they claim all is fine, and cant account for the slippage. They suggest i check out a transmission shop and have my 4th and 5th gears looked at.

Only thing is the car hasnt gone under any stress to cause those gears to suddenly fail.. it went into the garage with a worn down clutch that doesnt slip... and comes out with a NEW clutch that does slip.. makes no sense to me. Can anyone help me figure out what might be causing this? I do get the feeling my mechanic is trying to screw me over and save time/money for his shop, so i need something more to throw at him.

 

[FORMONTOYA]

Every time you swap in a new clutch you also need to adjust the pedal "free play".

The first clutch that went in my car was done by someone else and they didn't adjust the free play afterward. My problem was that after a few miles driving (getting a little heat in the clutch) the clutch would slip, but only in 4th or 5th if I was accelerating on the freeway. Took it back, they adjusted the pedal, and all was fine.

Take it back and have him check that out.

 

[PieEyedPiper]

I'd start with adjusting the pedal myself, before taking it back.

 

[acapella187]

^I third that
Sounds exactly like what I had. 2min to fix

 

[ClassicalBor]

so are you suggesting that its the pedal itself, and not the engage point or anything with the slave cylinder?

 

[ClassicalBor]

as in the pedal is not disengaging all the way out on its own and i need to adjust how for out from the floor it comes and/or compare it to where my brake/gas lines up with it?

 

[FORMONTOYA]

http://www.roadraceengineering.com/clutchandflywheeltech.htm
Toward the bottom of the page, "clutch adjustment".

 

[ClassicalBor]

Thanks formon, im gonna check this out myself along with my mechanic as well. is it possible that this kind of slip could be on all gears, not just 4 and 5, and the ratios on them quick enuf to experience and over come the slip before its really noticable?

 

[FORMONTOYA]

I guess it could.

When my first clutch went in and I had the problem, I noticed it after about 2 minutes on the freeway right after I left the shop. I turned around and went back to the shop and they fixed it.

Once I noticed it slipping I was easy on it for the trip back, so I couldn't say about the lower gears.

 

[ClassicalBor]

After adjusting the free play a couple times at different distances the clutch is still slipping, adjusted it from about 1.5in off the floor to practically on the floor with the same scenario. I DO have a leaky master cylinder that im getting replaced tomorrow which im sure was a factor in the pedal itself coming back a little slow... but still confused a bit as to why my clutch slips under certain throttle scenarios in gears 2 - 5... only way i could test gear 2 and 3 were to shift into them at very slow speeds and once it grabbed to about 2k rpm nearly flooring it.. notice the slip is very fast in 2nd.. nearly too fast to allow it to grip.. 3rd slightly smaller... 4th smaller 5th smaller... so on...

The clutch is warrented and i can get a new one, but i dont wanna jump to the fact that its a faulty clutch.

 

[DiamondStarAwd]

Could the shop have got grease or something on the clutch casuing it to slip under heavy load. You dont expierence the slippage in first in 2nd b/c it doesn't take that much tq to get the car moving. alot more tq/load/harder when stepping on it in 5th at 50 mph then in 2nd at 25.

 

[ClassicalBor]

OK i am still dealing with this slipping clutch problem the past week ive been trying a few adjustments and such (not directly on the clutch tho) and it is still slipping. I figure this might help you guys diagnose the problem with me

The clutch replacement installed by a Napa Mechanic garage is the following:

Item Number:
NNC
MU477351

Attributes:
# of Splines:20
Additional Contents:Clutch Disc
Cover Assembly
Release Bearing
Alignment Tool
Cover Size:8 7/8"
Cover Type: Diaphragm
Disc Hub I.D./Input Shaft Size:7/8"
Disc Material Type:Organic

Now i do not know what all of this means or if thats going to help anyone ### i dont see it listed with clamping force etc... but apparently this is the lowest on the list.. There are stage 1, 2, 3, and 4 Hi-Performance clutches available from Napa as well.. They are:

Item#: NNCF1122 (Hi-performance Stage 1)
Attributes:
# of Splines:20
Additional Contents:Clutch Disc
Cover Assembly
Release Bearing Assembly
Alignment Tool
Clutch Size:225mm
Cover Type: Diaphragm
Disc Hub I.D./Input Shaft Size:22.4mm
Disc Material Type:Carbon/Kevlar

Item#: NNCF2122 (Stage two hi-perf.)
Attributes:
# of Splines:20
Additional Contents:Clutch Disc
Cover Assembly
Release Bearing Assembly
Alignment Tool
Clutch Size:225mm
Cover Type: Diaphragm
Disc Hub I.D./Input Shaft Size:22.4mm
Disc Material Type:Kevlar

Should I have gone for at least a stage one? or do i still need more clamping power? My turbo is boosting 15-16pounds and the only speed mobs i have are intake, intercooler piping, exhaust. Is it true that the standard replacement low end clutch is just toooo shitty to handle my kind of power? It is under warrenty so i am going to try an upgrade it to at least the stage 1 and pay the price difference.

Also the Napa item warehouse dealer sent an Exedy05048 clutch which is apparently for 2.4L eclipses that shit wont line up will it? or have the clamping force i need... I think I need to just upgrade my Napa stock clutch (which i think is used for more than just my application, i dont think its model specific so might not hold the power i need) to a stage one. What do you guys think??

 

[ClassicalBor]

what i meant about the exedy clutch is... they sent it to be used as the warrenty replacement but its product code lists only 2.4L, for OEM replacements.. so its gotta be sent back, sorry for confusion

 

[blackrosenova40]

Leaky rear main seal