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1985 G63b 4spd clutch issues

Posted by 1985D50, Aug 3, 2020

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  1. 1985D50

    1985D50 Probationary Member

    11
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    Joined Jun 19, 2020
    Medellin, Oregon
    I was having starting issues. It got fixed but the starter wasn't catching the ring gear solidly. I have a new starter and put in a new flywheel and an old new clutch that was on the shelf in my shop. It starts great now but the clutch did not work. This is only my second clutch job.
    It was pretty obviously not contacting the fingers on the pressure plate when I pressed the clutch pedal.I adjusted it all the way out and it barely worked. Also when I installed the pressure plate it was super tight on the flywheel pins and as I tightened the 6 bolts the finger on the side near the bolt I was tightening compressed as if the throw out bearing were pressing on it.
    I removed it the clutch and compared the pressure plate to the one I took out with the old flywheel. It looked shorter with the flat face down and measured 1.5", .25" shorter than the one I took out. I thought maybe it was a mistake clutch which is why the sender never asked for it back. So I got an M Pact from RA. I measured the pressure plate on it when I received it and it was the same 1.5". I did not try to install it I just sent it back. The Valeo pressure plate I took out measures 1.75" to top of the body flat face down not the fingers.
    I cannot find any references to this measurement and a clutch shop I called told me to call the manufacturer.

    One more thing the pressure plate hole for the flywheel pins are very tight. Is it OK to make them bigger so they slip on without having to use force?
     
  2. randman2011

    randman2011 Proven Member

    259
    76
    Joined Feb 26, 2012
    Indianapolis, Indiana
    Can you provide pictures of the measurements that you are taking? I'm having trouble understanding what you're describing.
     

    Street Build 1K  1

    1998 Mitsubishi Eclipse GSX
    awd · manual · 2G DSM
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  3. 1985D50

    1985D50 Probationary Member

    11
    4
    Joined Jun 19, 2020
    Medellin, Oregon
    Here ya go. I've been pondering and the inside diameter of the pressure plate I had is 5 7/16 and the new one is 5 3/8. Also the clutch discs are very different. I had not paid very close attention to them until I just went out to take the picture for you. Second picture left disc is the old one that worked. I also just saw a stamp on the new one that says Valeo. I may just put the old one back in since it has low miles on it anyway.
     

    Attached Files:

  4. randman2011

    randman2011 Proven Member

    259
    76
    Joined Feb 26, 2012
    Indianapolis, Indiana
    The pressure plate is indexed to the flywheel using the three dowel pins. As long as you have all three, you can open up the bolt holes if you need to, but I'm beginning to wonder if that pressure plate is for a different application. The overall height of the pressure plate doesn't matter as long as it isn't so tall that it contacts the clutch fork. The important dimension is the height between the mounting surface and the fingers.

    The fingers on the pressure plate should (if they move at all) move outward during tightening, not inward. It definitely sounds like something is up with this pressure plate. When not installed, are all fingers at the same height and are all equally difficult to press by hand?

    Can you also confirm that the larger clutch disk fits inside the pressure plate without the inner metal part contacting the friction surface? As long as that clears then either disk should be fine to use. It may just be the angle and lighting, but the disk on the right looks like it has quite a bit more friction material left on it.
     

    Street Build 1K  1

    1998 Mitsubishi Eclipse GSX
    awd · manual · 2G DSM
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  5. 1985D50

    1985D50 Probationary Member

    11
    4
    Joined Jun 19, 2020
    Medellin, Oregon
    The new flywheel has 3 pins the old one only had two. I was thinking it might allow for the bolts not to suck it up tight to the flywheel but all info I can find requires the pressure plate to be flush with the flywheel.
    Not for nothing I measured the disc that worked (it had not registered with me that it had 6 springs as opposed to 4) and its 8.5 inches not 8 7/16. So I found a kit on Carparts.com Perfection clutch. It has the 8.5 disc and is guaranteed to fit. I hope that also means work. :) I still think the pressure plate height has something to do with my problem but I have only found one person on YT who mentions that distance and he is talking about wear making things not fit as tight making that distance longer. Anyway the one I took out is still in pretty good shape. I can always put it back in. I was just trying to use best practice and give it a new clutch with the new flywheel.
    The one that did not work may be failed because I had to clean up the rust from sitting around for 10 years and the Ospho might have grown some iron oxide that stuck something together internally to the pressure plate or the disc.
     
  6. 1985D50

    1985D50 Probationary Member

    11
    4
    Joined Jun 19, 2020
    Medellin, Oregon
    I solved this problem by installing my old clutch. I have a new problem. The tail of the transmission and the driveshaft have have cups on them that keep the mating point clean in operation. One or both of them is out of round and the rubbing is very noisy. I thought I was dragging something metal. I need to know the proper name for these parts as the FSM depicts the one on the trans and does not name it. And I need to know if there is a fix other than replacing them.
     
  7. 1985D50

    1985D50 Probationary Member

    11
    4
    Joined Jun 19, 2020
    Medellin, Oregon
    The problem I think I have with getting a correct clutch aside from the height of the pressure plate is the throw out bearing being different as well. I am adding a picture of the throw out bearing I have and the one in the kit I just sent back. Mine is on the left. The springs would not hold the new one in place when I moved the fork lever to test it.
    The second picture is of the piece of wood I had made to fix the dust covers at the slip yoke. I got it started with a hammer then using a vice and a torch to heat it up I pressed it all the way in bit by bit. Worked first time.
     

    Attached Files:

    DJRace likes this.

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