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Yet another 1g clutch issue

Posted by jerrylarsen, Aug 14, 2019

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  1. jerrylarsen

    jerrylarsen Proven Member

    149
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    Joined Nov 23, 2014
    arvada, Colorado
    Hey all, long time but somehow the dsm’s pulled me back in.

    I’ve read hundreds of threads probably thousands of posts and no one has had anything that has fixed this issue.

    So it’s a 91 gsx act clutch and flywheel, new pivot ball, fork, slave, master, stainless line, the clutch petal has almost no free play, pressing the clutch has an immediate response from the master rod.

    I’ve hand bled, bench bled, power bled and no difference. 3 big bottles

    Adjusted the master rod to the very last thread (can still push the slave into its self)

    I suppose it could be a pivot ball shim issue, as the clutch fork when viewed from the front is slightly to the passenger side, and from what I can tell it should be slightly toward the drivers side.

    I’m running out of ideas once again, just trying to cover all my bases before I pull the transmission. As of right now the clutch will barely let me have any gears, has to be matted as hard as you possibly can and it will catch 1/8” of an inch off the floor.

    So what do I do, thank y’all In advance for any information!
     
  2. er82

    er82 Proven Member

    221
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    Joined Apr 18, 2014
    Sacramento, California

    Street Build 503  3

    1992 Mitsubishi Galant VR-4
    12.358 @ 113.78 · Galant VR-4

    1K  1

    1990 Eagle Talon TSi AWD
    manual · 1G DSM
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  3. jerrylarsen

    jerrylarsen Proven Member

    149
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    Joined Nov 23, 2014
    arvada, Colorado
    That is how I bled it yes,

    No it is not hitting the transmission when fully pressed
     
  4. Mello

    Mello Proven Member

    947
    232
    Joined Jul 4, 2003
    Albuquerque, New Mexico
    Are all tranny bolts installed & properly tighten including the one that goes in opposite from normal by the rear roll stop?
     
  5. jerrylarsen

    jerrylarsen Proven Member

    149
    5
    Joined Nov 23, 2014
    arvada, Colorado
    Yes, all trans bolts are installed and torqued to spec
     
  6. wrencher

    wrencher Proven Member

    319
    31
    Joined Nov 20, 2005
    Chicago, Illinois
    No excessive clutch pedal shaft wear?
    For diagnostic purposes have you tried a longer pushrod?

    Or flywheel not machined to/within .610 spec?
     
  7. pauleyman

    pauleyman DSM Wiseman

    5,147
    1,007
    Joined Nov 19, 2011
    oklahoma city, Oklahoma
    You didn't mention flywheel step. So what is it and what is the spec for your combination? how did you actually check the clutch pedal ? Even a bad pedal will move the master immediately. You have to physically check play. Pressing the pedal is not how you do it. At a bare minimum pull up on the pedal when it is at reat. If it pulls up you likely have a problem. That test is not definitive. Best to check movement of the pedal and lever relative to each other.
     

    Street Build 3K  1

    1997 Eagle Talon TSi AWD
    awd · manual · 2G DSM
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  8. Dhan

    Dhan Supporting Member

    898
    127
    Joined Apr 29, 2010
    Denver, Colorado
    What type of clutch disk and what kind of pressure plate?
    Is it a South Bend kevlar clutch?
    Is the flywheel stock or an aftermarket?

    Could be a worn pedal assembly or like Pauley said, improper step height of flywheel for the particular clutch setup you're running.

    But before you tear out the transmission again, have you tried replacing your master cylinder rod with a 2g master cylinder rod to see if that at least allows you to get it into gear? The 2g rod is longer and allows you an extra inch of thread of adjustment. It's easy to remove the rods, just a clip in the back of the master cylinder. Get one from Advance or O'reilleys or whatever is close by. This 2g rod is just a band-aid and doesn't address the real issue, and even if it works, you'll probably have clutch drag issues, but if it works, then I bet your pedal is okay and the issue is flywheel step height.
     
    Last edited: Aug 15, 2019

    2K  4

    1992 Eagle Talon TSi AWD
    awd · manual · 1G DSM
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  9. jerrylarsen

    jerrylarsen Proven Member

    149
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    Joined Nov 23, 2014
    arvada, Colorado
    I have tried a longer slave rod, no difference. I made the awful rookie mistake of assuming that a new flywheel would’ve been made properly, going to remove and recheck soon
     
  10. jerrylarsen

    jerrylarsen Proven Member

    149
    5
    Joined Nov 23, 2014
    arvada, Colorado
    Clutch is act 2600 flywheel is an act as well,

    Pulling up in the petal it appears the seems to have no effect on anything. Maybe 1/2” of play up and down that feels loose, hardly any different than my daily driver.

    Looking at the lever it appears to move as the petal moves, no noticeable slop
     
  11. jerrylarsen

    jerrylarsen Proven Member

    149
    5
    Joined Nov 23, 2014
    arvada, Colorado

    Top two questions are answered above I think,

    I will try the 2g rod next, before pulling the transmission.

    I believe it’s the flywheel step, as pulling the carpet out gave me enough to barely barely get it into gear
     
  12. Dhan

    Dhan Supporting Member

    898
    127
    Joined Apr 29, 2010
    Denver, Colorado
    Any update? You get a chance to sample what the 2g rod does to the setup yet?
     

    2K  4

    1992 Eagle Talon TSi AWD
    awd · manual · 1G DSM
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  13. jerrylarsen

    jerrylarsen Proven Member

    149
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    Joined Nov 23, 2014
    arvada, Colorado
    Got it in yesterday and clutch works kinda, trans still grinds and occasionally pops out of gear, so I’m gonna run it as is until I can get a new transmission that’s “good”
     
  14. Lucky13

    Lucky13 Supporting Member

    100
    9
    Joined Nov 20, 2002
    Palm Beach Gard, Florida
    Have you tried replacing the shifter bushings at the trans with solid ones to remove any slop there?
     
  15. pauleyman

    pauleyman DSM Wiseman

    5,147
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    Joined Nov 19, 2011
    oklahoma city, Oklahoma
    Did you check the pedal assembly as I described
     

    Street Build 3K  1

    1997 Eagle Talon TSi AWD
    awd · manual · 2G DSM
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  16. jerrylarsen

    jerrylarsen Proven Member

    149
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    Joined Nov 23, 2014
    arvada, Colorado
    Yes I have, no change
     
  17. jerrylarsen

    jerrylarsen Proven Member

    149
    5
    Joined Nov 23, 2014
    arvada, Colorado
    Yes I did, little to no slop in the petal, won’t pull up at all, the actuator arm seems to move instantly when the clutch is pressed
     

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