Clutch disengagement issues, incredibly confused.

[hubbazoot]

So I've already read this post...
http://www.dsmtuners.com/forums/newbie-forum/262833-clutch-disengagement-issues.html
and I'm having a very similar issue. Initially, the clutch wouldn't disengage. So I replaced the pedal assembly and that fixed the issue for a short while. After that, the pedal was getting so insanely hard to push down, it was basically impossible and it had a really inconsistent disengage point, so I've replaced the clutch master. I have a brand new clutch master in the car, and I can't get the thing adjusted so that I can actually disengage the clutch. If I turn it too far out (so the engage point is further off the floor), it makes a scraping sound when I push the pedal all the way in. (clutch pieces scraping). So I started letting my foot off the floor and finally got it to the point that I could disengage the clutch.

Here's what was happening when I had the pedal "overadjusted."
(Clutch pedal on floor, in gear) Scraping noise can be heard. Cannot engage/disengage.
(Clutch pedal slightly off the floor, in gear) Scraping noise goes away, can engage/disengage.
(Clutch pedal continues to come up) Typical clutch engaging here, no problems.

Now what's happening is that middle step up there where the clutch disengages just doesn't seem to be there. Here's my specs:
- Stage 1 racing clutch/p-plate
- Rebuilt tranny with new bearings and synchros everywhere.
- Resurfaced flywheel (I checked milling measurement, it's good.)
- New throwout bearing
- Shimmed pivot ball
- BRAND NEW aftermarket clutch master. (This is the fourth one on the car since the tranny rebuild.)
- New pedal assembly, and it's still good.

Up until I started having these problems with the clutch, the transmission was shifting perfectly. Clutch/transmission have about 9000 miles on them now. I've just gotten so completely frustrated with this problem, I really am clueless as to what's going on. Help?

 

[1990AWD]

Well let's go over the basics

You said the pedal assembly is good
Check again for leaks at both master and slave
Properly bled the system and fluid is up
Get a friend to move the clutch and watch to make sure the slave is moving and holding
Adjust the master rod for optimum travel

Here's a good video to explain how it all works and to properly adjust the master http://www.youtube.com/watch?v=vYJxQyjIhUw&feature=youtube_gdata_player

 

[hubbazoot]

Well let's go over the basics

You said the pedal assembly is good
Check again for leaks at both master and slave
Properly bled the system and fluid is up
Get a friend to move the clutch and watch to make sure the slave is moving and holding
Adjust the master rod for optimum travel

Here's a good video to explain how it all works and to properly adjust the master YouTube - Proper Clutch Adjustment

Yes, brand new assy.
Master and slave are in excellent condition. When I say the master is new, I mean like 20 miles installed new.
Yes, completely bled.
Did that when I bled it.
I've done all of this.

I'm only a newbie to the forum, not to cars. As for that "god" Jack that everyone loves so much...

 

[rza808]

this might sound off the wall, but have you pulled the clutch to see if you busted the springs off the disk? they might be stuck somewhere in the clutch causing you problems.

 

[95talongirl]

+1

I was completely frustrated with disengagement issues for weeks on end until one day decided to look at the clutch and found that fingers broke off the pressure plate. Clutch had 8k miles on it. So mileage doesn't mean much...

 

[hubbazoot]

this might sound off the wall, but have you pulled the clutch to see if you busted the springs off the disk? they might be stuck somewhere in the clutch causing you problems.

+1

I was completely frustrated with disengagement issues for weeks on end until one day decided to look at the clutch and found that fingers broke off the pressure plate. Clutch had 8k miles on it. So mileage doesn't mean much...

Sounds reasonable. I haven't pulled it yet, but I can do that here in a couple weeks. Far too busy until then.

Update: Seems to disengage relatively okay while I'm driving, but only really has problems when it's stopped. The faster I'm going, (5000-7000rpm shifts) the better it generally gets. It'll hardly go into gear and I usually have to turn the car off at the light to get it into gear. Once I get moving, though, it's fine.

 

[hubbazoot]

Update: The clutch got so bad tonight it would hardly disengage enough for me to stop. I managed to get it home, but now it's gotta come apart. I'm thinking it's the clutch plate itself or the pivot fork that needs replacing. Any suggestions on what type of clutch to order and where to order it from?