Clutch Cable Replacement/hydro Conversion

[Fresbone]

I got everything buttoned up, charged the battery, and adjusted the clutch… and it doesn’t work right.

When the car is off, I can shift into every gear. When I have the car in neutral and the clutch pedal is depressed, everything is fine. When I let out the clutch pedal and the transmission is in neutral, I hear a grinding noise. When I keep the clutch pedal fully depressed and try to shift into reverse, there is a whirring noise that definitely is coming from the transmission. With the car running and the clutch fully depressed, I cannot shift into 1, 2, or 3. TC is in 2W.

Any ideas?

 

[vtxtasy]

Clutch disc in backwards? That is what it sounds like. Very common mistake.

 

[Fresbone]

Clutch disc in backwards? That is what it sounds like. Very common mistake.

It wasn’t doing this before and I didn’t take off the pressure plate. Any way to tell without taking everything apart?

This is as far as I broke it down.

 

[OzFin]

I use Luk clutch kits and I have intentionally attempted to put the driven disc in backwards just to see if it is possible and found that the spring cush drive hub is it too big to fit into the center of the flywheel, It could not go in backwards.
Perhaps other brands could, but with all of the Luk I ever have used this wouldn't be possible. It would be very apparent on assembly that it is not correct.

With the vehicle not running, have a helper cycle the clutch pedal in and out while you are underneath observing the the mechanical action of the release arm, use a flashlight and look into the release arm window of the bellhousing. Observe the release arm for the distance it moves. Check to see if the new arm has come in contact with the clutch pressure plate cover. Other than the hydraulic slave actuating the release arm the last variables introduced were the new release arm and bearing, l would focus on checking those for proper operation.

 

[Fresbone]

I think there were two problems, and one is now solved.

I think the connection between the slave cylinder was too tight. Photos on the internet show the nuts and cone washer in a different orientation from the Partsdude photo.


I think the top picture makes the most sense. I had it assembled like the lower image and that kept the end of the slave from pivoting a little. Loosening the nut to the left of the cone washer solved the problem of whirring noise when I tried to shift into R and the inability to shift into 1, 2, or 3. Or it coincidentally stopped after I did that.

 

[Fresbone]

There is still a noise when I let out the clutch pedal. I put the car on the lift, started it up, and let out the clutch while a friend was checking below. It is coming from inside the bell housing. I can propel the car when the clutch isn’t all the way out (obviously not going to do this).

 

[Andrew Theros]

There is still a noise when I let out the clutch pedal. I put the car on the lift, started it up, and let out the clutch while a friend was checking below. It is coming from inside the bell housing. I can propel the car when the clutch isn’t all the way out (obviously not going to do this).

You never touched the T14, is that right?
With the clutch out the TO shouldn’t be spinning. I have heard that this noise is either T14 input bearing or needle bearings on the front shaft.

 

[Fresbone]

You never touched the T14, is that right?
With the clutch out the TO shouldn’t be spinning. I have heard that this noise is either T14 input bearing or needle bearings on the front shaft.

I took the T14 out along with the TC to access the bellhousing. I didn’t make any intentional changes to the gearbox.

Someone on the forum did question whether the friction disk was out of alignment, so I inserted the spline tool to make sure everything lined up.

 

[Fresbone]

I think I figured out the whirring noise when I let out the clutch.

This is a view through the bellhousing window. Note the area of wear on the clutch fork.


This is the surface of the clutch fork in the bellhousing, opposite orientation.


I think this is what is rubbing up on the clutch fork.


That being said, I don’t know the best solution. I’m going to call Novak tomorrow.

 

[Militarymetal]

Dang man! You’ve been fighting this for a long time! Persistence!