Very Low Clutch Pedal ACT2600

[LaserRS92]

Ok, I have a 92 Laser RS AWD 5spd. Has installed an ACT2600 clutch with sprung street disk, oem throwout bearing, clutch fork, and pivot ball, and extended slave rod. Car has 850 miles on this setup since it was pulled from Detroit and rebuilt. When the trans came out of the car after sitting for a year it had a broken 1-2 shift fork and two shims under the clutch pivot ball. With the act2600 clutch those two shims caused the clutch fork to hit the pressure plate. Both shims came out to fix that.

Drove car as is for 850 miles, clutch was real low on the floor, releasing right off the floor. Slave died next. In went oem unit with dorman clutch master, extremepsi braided clutch line, and extended slave rod off old slave. After gravity bleeding system and the pump up bleeding style the pedal is just as low before, no improvement at all. Feel is improved from braided line however.

Question is, is there a pressure plate that would be shallower or something and allow the pivot ball shims better than my current act2600, is it flywheel runout issue, or would a new trans fix things since every trans is different?

 

[LaserRS92]

Yes this is the same used ACT flywheel, I personally told them the specs when I dropped it off at the machine shop. I saw on the paper work when I picked it up the machinist notated how much he took off and the current step height.

The fork visually looked the same and uninstalled and installed the same. Again the fork only has 1000 miles. Slave and master are oem, have maybe 200 miles.

I've had three different dsm owners verify adjustment is where it should be, it is. Fork in boot is right at center or just to the right of it. Haven't been able to find any slack in pedal assembly.

Only thing I can figure is 1: used flywheel which has been machined a couple times I assume while having the same step height has less material which is affecting clutch finger placement and 2: send out pedal assembly for welding?

 

[talon1990TSi]

your problem is your master cylinder rod is maxed out. If you want you can put a bolt on the end and add a stud. Just have the nut welded on both ends that way your stud wont come off. My shell had one like this in it. I took it out and replaced it with a new one. ever since its been close to off the floor. but I will say you are going to be taking a chance of bending the fingers on your PP. Just leave it alone and deal with the pedal where it is now.

 

[NHerron]

Only thing I can figure is 1: used flywheel which has been machined a couple times I assume while having the same step height has less material which is affecting clutch finger placement ...

That could be a factor also, however I do not know the spec for it. Maybe air in the system, or leaking slave/master cylinder?

I wouldn't let it stay that way, it would drive me crazy knowing the car left the factory working properly. So there is obviously a fix, it's just finding what fix that is

 

[LaserRS92]

NHerron that's what's bothering me, my old 92 Laser RS Fwd was completely stock parts at 167k miles and felt great. My minty 98 Civic almost rivals it.

While the act flywheel could have a material height issue the point I am also realizing is that the issue was still apparent before the new flywheel, so it was preexisting in the mix of parts including the stock flywheel that were already on there. I haven't done pedal assembly yet so maybe that's next. Or a new master cylinder.

Or auto swap??

 

[NHerron]

To me, if the fork arm is still centered (or better -towards the driver side) after pumping the clutch a few times, you're good everywhere past the fork. That being the ball, socket, TOB, PP, disc, FW, and thrust bearing. I would point to something BEFORE the bell housing components in other words

I can't remember how far the fork end moves when the clutch system is functioning properly, but I can take a video of mine for reference if you want to see. That would give you something to compare against at least

 

[LaserRS92]

I'm thinking about taking out the extended rod and pivot ball shim, and looking at possibly another master or slave along with a clutch pedal assembly. After that there is nothing left.