URGENT! Need help with clutch install!

[AllShallPerish]

97 GST with 7bolt,

Clutch went out last week i got it towed to a shop to install a new one..

They just called and said they have the new clutch installed but there is an inch of extra room between the clutch fork and the slave cylinder, with the pedal depressed all the way the cylinder wont hit the fork.

They are a major transmission shop and they said they never seen anything like this before. All the parts match up and its not fitting, he said the clutch fork is no where near the slave cylinder.

What can cause this? He thinks the fork is too short..

he wants me to call him back and help him figure this out because they are stumped.

Thanks

 

[AllShallPerish]

Ok, I am going to go back over there tomorrow and look at the slave. get part numbers of the new clutch.
Thanks for the offer but I am going to get a T.o.B overnighted from extremepsi.

 

[jimbob_843]

Sounds like a plan. Shit we can walk you through the install if need be. Its a shame a transmission shop cant figure out the problem and your paying for it.

 

[AllShallPerish]

I know man, its depressing... I could have learned how to do it myself and saved a ton of money.. The only thing is, i live at the beach so my driveway is sand.... Cant even change my oil (i use walmart parking lot).

I want to go in there with a list of things to look at so i can systematically cross them off the list.

1. Check slave cylinder,
2. Check pedal, adjust rod clockwise if needed
3. Find out part number and brand of clutch
4. get OEM TOB
5. ?

Please add to the list if you can, this way we can make sure to cover every aspect.

Also, how can i check the master cylinder? Is it possible for the seals to blow out and not lose any fluid?

Thanks

 

[95eclipser]

any luck figuring it out?

 

[AllShallPerish]

Just got back
It is a luke clutch, # 05-048 new pressure plate.

Slave looks fine, the rod compresses no problem.

I want him to put it back together so i can see what exactly is going on.... He is describing it to me, and it doesn't make too much sense...He is still set on the flywheel being wrong....

I am guessing the fork is just sitting to far on the passenger side, and needs a shim or 2...

 

[bradselph]

If you weren't almost 200 miles away i would come do it for ya.

Its gotta be something insanely stupid.

 

[AllShallPerish]

If you weren't almost 200 miles away i would come do it for ya.

Its gotta be something insanely stupid.

My money is on either, pivot ball needs a washer or 2. Or, he didnt have the dowel pins lined up correctly.

 

[kidtsi]

Then it you need shims, the fork is hiting you bell housing.

 

[TurboTsiThatFly]

I had this same issue a few months back. I had to shim my pivot ball a 1/4 of an inch. Maybe you need to do the same. I also had a brand new clutch, t.o.b, pivot ball, clutch fork, slave cylinder, clutch master cylinder. and everything. Nothing worked for me in terms of fixing it except for shimming the pivot ball. Cant hurt to try shimming it. Just my 2 cents.

 

[AllShallPerish]

Ok guys, so i went back over there and explained how the pivot ball works and showed him what adding shims does to the angle of the fork... O

He was so confused, but i think he gets it now. He is throwing it back together tomorrow, lets hope it works.

I will report back with the final conclusion.

 

[TurboTsiThatFly]

Ok guys, so i went back over there and explained how the pivot ball works and showed him what adding shims does to the angle of the fork... O

He was so confused, but i think he gets it now. He is throwing it back together tomorrow, lets hope it works.

I will report back with the final conclusion.

Make sure he shims the pivot ball enuff. To properly align the t.o.b to the pressure plate. Otherwise you'll wind up shearing off the pressure plates teeth. Just sayin..

 

[AllShallPerish]

Finally, car is fixed.....

A washer behind the pivot ball fixed the problem.

Thanks for the help,

 

[FireyIce01]

Finally, car is fixed.....

A washer behind the pivot ball fixed the problem.

Thanks for the help,

I just went through something very similar to this. I did the clutch myself, and on my way out of the garage my clutch fork broke (my slave cylinder WAS pushing it far enough that it broke the fork on the bell housing), so I ordered a new one from extremepsi, and got everything installed, to discover that the new fork wouldn't fully disengage the clutch... so, I had to take the transmission out of my GSX 3 times just cause I didn't pay attention to my buddy, who told me beforehand to get an OEM TOB and remember to shim my clutch.