TRANNSMISSION MYSETRY 1990 tsi

[djgalant]

Ok people. Here is the problem.
The car is 1990 eagle talon AWD tsi turbo.
I bought the ca about 6 months ago , and at the time the transmission did not work.
Friend of mine who is mechanic took out the motor and disconected the transmission from it, and quickly we find out that the throw up bearing was into peces and pressure plate was not in the best condition.
So I ordered ACT 2100 clutch set kit ( new NSK bearing, disc, and pressure plate) and friend of mine installed everything back. The car fired up, and the transmission after it was bleeded
was working fine.
Recently i i seized the motor.
So i got the jdm motor installed, and we installed mine transmission back.
Engines fires up nicely with perfect 150 compression on all cylinders.
I have no tachometer readibg though - due to different plug.

HERE IS THE PROBLEM!
After bleeding the clutch so many times, when car is on, the transmission grindes and doesn't go in the gear.
When car is off, the gears seems ok.
We changed the slave cylinder, put the one of my friend's car, then bleeded about 6 times more with no success, The tranny grides, and doesn't go intgo no gear,
It looked like the pressure plate problem, and my firnd decided to take evrything again apart to see what's up.
After taking the motor and tranny again out, everything looks visually ok.
Disc, pressure plate, fork , t. bearing, evruthing is in the excellent condition.
The transmission itself looks good too. The shafts are working right, the gears are comming in ,and everything.

My friend coudn't believe that this didn't work and called his other buddy who works for dodge dealer as a mechanic to see what's up.
The guy looked at evrything and said that everything looks good to him.
WTF????
Have any1 experienced anything like that before?
Of course when tranny was installed we checked the pressure for master cylinder and checked the cables also.
WTF???
Plese lhelp me here.
IS there anything that i can do to make this work?


The only concern that imay be the problem is the flywheell that came with that jdm motor.

 

[pneumo]

If the tranny shifts fine when the engine is off, but it won't shift when the engine is running. that's definately a clutch issue. If the clutch isn't disengaging completely you won't be able to put it in gear.

Do you still have the original flywheel? Compare the step height on the JDM flywheel. Check the clutch pedal adjuster rod under the dash to make sure it's adjusted so it pushed the rod all the way into the master cylinder. Check the clutch fork and pivot ball in the bellhousing to see if they're worn. With any clutch it's a good idea to put a lockwasher under the pivot ball to help with clutch disengagement.

 

[djgalant]

the original flywheel is gone. I trashed it, because it had some major cracks.

That is exately what my friend said - the problem with disangening the clutch.

Could you explain more about putting a lockwasher under the pivot ball to help with clutch disengagement. WHat kind of lockwasher and what is apivot ball anyways?
Thank you.

 

[pneumo]

It sounds like you've been bleeding the clutch a lot. Did you know you could drop the trans without unhooking the line? all you do it unbolt the slave from the bellhousing and move it aside.

The pivot ball is the fulcrum that the clutch fork pivots on. The slave cylinder pushes on a rod that pushes against one end of the fork, and the other end of the fork pushed on the throw out bearing. Adding a washer under the pivot ball helps the clutch fork push farther. A typical washer will work, look for something about 2 to 4mm thick.

Look for the tip of the clutch fork when the car is all put back together, it comes out of the bellhousing through a rubber boot that covers a square hole. You should also check to see if the fork is centered in that square hole. If it's offset to the passengers side that could be the problem. The lockwasher should fix that.

Did you resurface the flywheel when you put it on? A warped flywheel will also cause disengagement problems.