I went to shift the other day and my pedal went halfway, popped and then went almost to the floor. Now when I put it into gear the clutch has to be to the floor and the car shudders when I barely lift the pedal. Pedal pressure/resistance is about half what it used to be. Previous owner had a ACT 2600 put in within the last 10,000 miles if that helps.

Any ideas?

Start at the slave cylinder and see if there was any damage to the push rod and see if any thing happened to the shift fork as well. Did anything happen to the pedal itself?

If those appear fine it sounds that you'll need to pull the tranny to see what damage was done.

pedal is fine, looked up under the dash and didn't see any fluid leaking or anything amiss there, so hopefully the MC is ok, now to move on to the SC I guess.

The pedal has even pressure and comes back up when pushed down, it just has less resistance and the whole shuddering thing like something's not engaging correctly. I was reading in another thread where someone talked about breaking a clip on the throwout or maybe a fork issue, but they didn't update the thread with a result. I've never worked on a transmission, so I honestly don't even know what to look for

Bad thing is I don't want to move it in case there is something hanging on by a thread that is keeping it from blowing up

Check the clutch fluid, the master and the slave...if it's none of those, you may have to pull the trans.

Its possible that you popped a spring in the clutch disc out. My friend popped two of them out and he had similar affects

olmytsi said:

Check the clutch fluid, the master and the slave...if it's none of those, you may have to pull the trans.

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fluid looked good, hopefully I can check the slave rod soon. Not liking the prospect of pulling the trans, ugh.

Hcaruso4 said:

Its possible that you popped a spring in the clutch disc out. My friend popped two of them out and he had similar affects

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hmm, so not knowing anything about manual transmissions, would it still be in there bouncing around waiting to get caught somewhere are did it wind up out in the street? Can you just replace the springs or do you have to get a new disc?

Pull the transmission out. Unbolt the pressure plate. I bet you have some loose rattley springs
It is BAD BAD BAD to try to drive it like that. So don't even THINK about it.

No, it will still be in the trans bellhousing if it fell out, but I doubt it, you probably broke a spring in half.

It's real fun. I've had it happen to me twice now. It's possible it's also TOB related but you're really gonna have to pull the transmission. I can help out via pm or you can call me if you'd want personal help on the trans pull out.

Let me know.

A spring in the clutch disc wouldn't effect the pedal and make it go to the floor.

You're gonna hafta start checking everything in the system. Check the pedal itself, the cross-shaft it pivots on, the pedal arm - where it attaches to the shaft, and the adjusting rod. It's very hard to check while still in the car but the bracket assembly for the pedals sometimes crack, mine did. That's why Shep sells em.

You also could have broken a clutch fork, or even the bellhousing if the bolts have come loose. Have a friend press the pedal in and out (engine off) and check that the trans is not moving away from the block.

It's a mechanical problem so it shouldn't be hard to find, but you've got a lot of checking to do.

Rick - '91 GSX

You could have also split one of the two rubber o-rings on the clutch master cylinder piston. This can happen and still not leak out the master cylinder boot.

To find out if this is what happened, you would need to remove the clutch master cylinder from the vehicle, then remove the boot and remove the spring clip with a small flat-head screwdriver or pick tool. Then, you will tap out the piston and inspect the two rubber o-rings for damage.

You can pick up a rebuild kit from almost any parts store for pretty cheap.

You could have also broke a pressure plate spring.

twicks69 said:

You could have also broke a pressure plate spring.

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Man I'd like to see some pictures of that!

@4pistons. This has happened to me twice or three times. Definately could feel a difference in the pedal. But ok.

sorry for a lack of update, been super busy so the car has been sitting. I hope to start looking at it tonight. Going to check everything I can, but if it's in the transmission or clutch assembly, there's a good chance that it'll have to go to the shop. I'm not too excited to make a 2gawd my first ever trans drop/clutch experience.

took the slave off last night. Car running, pushed the rod in and had my wife press the clutch pedal, it never put any more resistance against my finger and when I let go of it, it just slowly releases itself, pedal pressed or not. Pedal still basically has very little resistance rod pushed in or not. Also, it looks like a little bit of fluid has come out of the master lid... blown seal in the master????

my luck, it's probably a combo of hyrdaulic and mechanical. $10 says that I'll change the cylinders, get pressure back, but still have issues and find fork/tob/spring issues.

If that's the case, another $10 that there will be a FS ad after I get it fixed

im having similar problems.... what did u find out? im going on my second sc replacement... with extended rod?

new slave and master installed, bled per http://www.dsmtuners.com/forums/art...how-properly-bleed-your-hydraulic-clutch.html , still pretty much the same, guess it has to go off to the shop

You said you can get your car into gear but you feel is shudder is that right? (clutch not fully disengaging - imo)

Does it ever grind going into first gear? I've had a similar problem lately, im determined its the clutch fork. Check your clutch fork position next to the slave, it should be mostly centered. If there is damage to the clutch fork it might still be workable if shimmed. You might be able to check this by removing the rubber boot around the fork and peeking inside the bell housing.

ClassicalBor said:

You said you can get your car into gear but you feel is shudder is that right? (clutch not fully disengaging - imo)

Does it ever grind going into first gear? I've had a similar problem lately, im determined its the clutch fork. Check your clutch fork position next to the slave, it should be mostly centered. If there is damage to the clutch fork it might still be workable if shimmed. You might be able to check this by removing the rubber boot around the fork and peeking inside the bell housing.

Click to expand...

yeah, it goes into gear with zero grind, and if you let off the pedal just a hair the car starts shuddering and there's a chattering sound coming from the tranny...

fork looks centered, slave pushes it all the way to the passenger side when the pedal is pressed to the floor.

Ah well if its shuddering when youre coming off the clutch pedal, then its def something inside your tranny, or a spring or the entire clutch itself. Mine is more like the opposite, engages fine when I come off the pedal, but it grinds going in occasionally.

finally got it in to a mechanic, survey says: one arm broken on the clutch fork, clip was holding the fork in enough to get in gear, but that's it. Springs looked ok, all are still in the plate.

mechanic also said that the clutch plate has hotspots on it, throwout bearing needs replaced, front u-joint needs to be replaced and the flywheel machined.

14yo clutch fork didn't like a new ACT 2600... hard to believe...

machining the flywheel to get any spots taken car of, and then he's going to put an OEM clutch kit back in it. Why the PO put an ACT2600 into a 100% stock 2g is beyond me to begin with.

$900 later and it shifts great, but I have hardly any pedal pressure. Goes all the way to the floor

Guess I'll call the mechanic back.

You're supposed to change the fork, the pivot ball and TOB EVERY TIME you change the clutch!

yeah, I don't know who the PO had do the work, but apparently they really cut some corners.... reused factory parts, probably didn't adjust the step, who knows.

still trying to figure out why the pedal goes to the floor with barely any pressure. The car shifts fine, but the pedal is sofffffffft. Maybe I'll do a quick bleed on it this weekend to see if there's any air in the lines.

500miles to break-in... only 495 more to go