Clutch won't disengage

[kc92awd]

1992 AWD 5-speed. I put an ACT 2100 in and it won't release when I push on the pedal.

I already tried bleeding it.

I put it on the lift and have some more information. It seems that the rod coming out of the slave cylinder does not push the clutch fork far enough. So, I put 3 nickels between the fork and the slave cylinder rod. Even with the added "spacer", I measured and the fork did not move any further. So it is like the slave cylinder just can't push hard enough.

The clutch is adjusted almost all the way under the dash. What do you think is the problem?

 

[GTM]

"Yeah, but it also helps confirm the real problem.
I've never heard of brazing. Can a muffler shop do that?"

I've seen too many mechanics and shade tree mechanics think they have solved the problem more than likely something else unlike this. It is possible for a master cylr to suck fluid past the seal and build up pressure when it gets hot. The result is the clutch doesn't release all the way and slips... not a good way to start off life. When you see that someone has tampered with the master cylr rod it's because there is another problem which they could not solve or didn't know how.

Brazing is good for some things including cast iron exhaust manifold cracks. You can't weld them for the alloys don't want to bond but the brass will, it's critical in the case of manifolds that you properly cool it down or it will crack more. Usually you drill an expansion hole at the end and fill with brazing rod. The shear strength is quite high (70-100 thousand lbs if memory serves) and more than enough for this application. It flows like solder, takes less heat, doesn't rust, and wicks unlike welding.

Yes a muffler shop can do this, I was expecting you would have had it done by now, it's a lousy 10 minute fix if you have a torch and decent quality brazing rod. Maybe you can rent a small torch from Home Depot.

Cheers,
GTM

 

[G-UNIT]

remove your front seat when doing this & you will save your back.

 

[kc92awd]

Problem solved

Thank you for your help oldman and GTM!

But now I have discovered a new problem. Car goes forward while it's in reverse.

http://dsmtuners.com/forums/showthread.php?p=1409528#post1409528

 

[GTM]

Problem solved

Thank you for your help oldman and GTM!

But now I have discovered a new problem. Car goes forward while it's in reverse.

http://dsmtuners.com/forums/showthread.php?p=1409528#post1409528

That's great,
you are welcome.
.......................

Don't tell me you put the ring gear carrier in upside down?????????

Hopefully it's just the shift cables.

Cheers,
GTM

 

[oldman]

Problem solved

Thank you for your help oldman and GTM!

But now I have discovered a new problem. Car goes forward while it's in reverse.

http://dsmtuners.com/forums/showthread.php?p=1409528#post1409528

You are welcome. check the shifter cable linkages underhood. Good Luck.

GTM I must said you're one of the more helpful wisemen I've ran into, Good job. Hopefully I'll run into you again when I need help.