Clutch Disengagement issues

[Midnight DSM]

This is what I posted on the link forums. Any help would be appreciated.

So I have a 91 AWD w/ 2.3, stock tranny, act 2600 w/ xact flywheel w/ approx 8,000mi on them. Clutch will not disengage. I have replaced the Slave cylinder, which was leaking so I figured this was the culprit. I have adjusted the clutch pedal to where it can not be adjusted any more. The master cylinder is in perfect shape and the slave push arm moves .641 inches when the clutch is pressed. I have removed the transmission and shimmed the fulcrum ball. I have replaced the ball with a new one and replaced the clutch fork with new. This started just this Sunday morning, I walked out to my car, started it and let it warm up like usual. When I pushed in the clutch and tried to put it into gear it absolutely refused to play. Nothing I have done has given me the answers that I was expecting. Please help me out. I want to drive my car and it won't even go into gear with the car running. With the car off, the transmission will shift gears just fine with nothing feeling out of place.

After being lazy for a couple of days, A friend and myself decided to pull the tranny again tonight and take a look at the clutch.

Pulled the tranny tonight. Everything seemed to be in good working condition w/ the clutch and pressure plate. The throwout bearing is moving on the shaft and has no play. The only thing that deserved some attention was the pressure plate when it was still attached to the flywheel. When the whole assembly was bolted together on the motor the fingers on the pressure plate were all nearly flat, when we undid the plate from the flywheel all of the fingers would change the degree in which they were pointing by probably30 degrees or so.

So picture this, when bolted onto the vehicle the whole pressure plate and fingers is flat like a saucer, when you unbolt the whole assembly the pressure plate now looks like a saucer w/ a boob growing out of the middle. (for those of you that didn't understand the degrees speach)

 

[95GSXBLUR]

I'm using an ACT2600 as well...

When tightened down, you are compressing the pressure plate against the disc and flywheel - you want this, this is what holds the power to the ground.

The blades will gradually go flat as you torque down the plate evenly. when you relieve pressure (loose bolts from pressure plate to flywheel) the fins will disengage and stick out like a boob.

That's normal. I'm not sure what exactly your problem is, however, My clutch setup is working fine and it goes from the fins out (like the boob) when loose, to flat fins when torqued down.

Maybe try extending the slave rod or replacing the throw out bearing. check to make sure your fork is moving all the way... with 8000 on them, you should have worn off a few hundredths off that disc... it should be disengaging.

also make sure you adjusted your clutch in the right direction as well...

Good luck man, but I think we're missing something - your clutch seems fine.

 

[19Eclipse90]

Agreed. The clutch sounds fine.
Are you using the stock clutch lines? If so, you may want to replace the soft line running in front of the transmission going to the slave cylinder. When it gets old, it will struggle to hold it's form, expanding with the pressure put on it when the pedal is depressed. This keeps the slave rod from traveling it's full distance. Had it happen on one of my cars - it may be something to look into.

 

[dsm-onster]

Where is your clutch fork resting while engaged; while disengaged?

Also you mentioned:

I have adjusted the clutch pedal to where it can not be adjusted any more.

Which direction did you adjust the master rod and lock nut? All the way to the end of the rod, or towards the firewall/cylinder?

 

[Dream On]

Check free play in the pedal assembly. Common problem on 1g's. Let it up all the way, and see if you can pull the pedal up with you hand any more. If you can, you need to pull it and weld the assembly.

 

[Midnight DSM]

Check free play in the pedal assembly. Common problem on 1g's. Let it up all the way, and see if you can pull the pedal up with you hand any more. If you can, you need to pull it and weld the assembly.

That was actually the first thing I tried. The pedal assembly is in perfect shape.

 

[NOFX0617]

My car had the same problem and I just fixed it. I couldnt figure it out but it ended up being that I had the clutch pedal too far out and the clutch would disengage but then then the fork would continue to push as I was pushing the pedal down and so the clutch went too far. Try maybe getting it into gear with the pedal halfway pushed in and keep trying to adjust it.