Clutch Pedal Adjustment/Free Play

[OneJArpus]

Here's my problem and parts list.

Just finished swapping in a 1J and i've been trying to work out the kinks. I can start the car no problem but can not throw it into gear when it is running. I can throw it into gear when it is off. But if i turn it on (while holding the clutch) the car jerks cause it is in gear and the clutch pedal isn't disengaging the clutch.

All parts new from DM
New master cyl
New slave cyl
New 1pc braided clutch line
Resurfaced flysheel
New clutch & PP (ACT Street disk)
TO bearing installed proper per TSRM

I am having a hard time trying to figure out how to adjust the pedal height and free play. I'm looking at the TSRM and i adjust the height. Then when i go to do the free play i'm kind of lost. I turn the rod i get some free play but it seems like it does nothing. I turn the car on and its still not shifting into gear.


Any help would be appriciated thanks

 

[Davismj711]

Hope this helps.

When I adjust my free play I remove the pin, and then turn the threaded shaft that is attached to the master cylinder. Re insert pin and look at free play.

Also, I am guessing you bled the system well.

Remove inspection cover on bell housing. Have an assistant work the clutch pedal. Make certain you are getting travel with the slave fork combo.

GL

 

[OneJArpus]

Hope this helps.

When I adjust my free play I remove the pin, and then turn the threaded shaft that is attached to the master cylinder. Re insert pin and look at free play.

Also, I am guessing you bled the system well.

Remove inspection cover on bell housing. Have an assistant work the clutch pedal. Make certain you are getting travel with the slave fork combo.

GL

I have taken the pin out a few times but it does nothing still.... I will have to wait for my buddy to get home so i can jack up the car and look under it.

Guess i'll bleed it one more time then look at the slave/fork combo.

Dammit! 6:20 pm! Snow flurries WTH!?!?! Shit its cold outside too!! UGH!

 

[OneJArpus]

Hope this helps.

ok i ended up checking it myself. Shit was it hard. A qt or oil to press in the clutch while im laying on the floor looking at the assy.


The throw out bearing and fork work perfect. I see it moving. The only thing i cant confirm is if the surface of the PP comes off the clutch. I have to wait on my friend for that.

I rebled the system and there is NO air and 100% new fluid. Still doing the same thing. What else can it be?

Could I have tightened down the PP too much for this to happen?

HELP Damn its cold!

 

[OneJArpus]

ok i ended up checking it myself. Shit was it hard. A qt or oil to press in the clutch while im laying on the floor looking at the assy.


The throw out bearing and fork work perfect. I see it moving. The only thing i cant confirm is if the surface of the PP comes off the clutch. I have to wait on my friend for that.

I rebled the system and there is NO air and 100% new fluid. Still doing the same thing. What else can it be?

Could I have tightened down the PP too much for this to happen?

HELP Damn its cold!

ok my friend came by. I inspected the trans again. Everything moves perfectly. Nothing is binded. The clutch was bled for a 2nd time today no air. I adjusted the height its right on. The freeplay is on give or take.

Still doesn't shift into any gears WTF!.

I looked at the TSRM for the R154 and it says this. The spline shaft was clean of all dirt and regreased. The trans is unconfirmed if in working condition. It shifts perfect when off tho. I got the trans with my engine when purchased from drift motion.

 

[MK3.0dudeman]

you can't get it working cause your a old school noob(thats worse than just being a noob)

 

[OneJArpus]

you can't get it working cause your a old school noob(thats worse than just being a noob)

don't clutter my thread with non-sense. I need answers not sarcasim from a youngin....:evil2:

 

[MK3.0dudeman]

grind gring grind is all I hear

 

[OneJArpus]

grind gring grind is all I hear

Learn to drive then. Sucks you keep grinding.


My car cant get into gear so no grinding here.

 

[MK3.0dudeman]

oo well it sounded like it.I'm getting out of my chair now and will be down in 3minutes and 42 seconds

 

[OneJArpus]

Can someone please help me! This is the only thing stopping me from driving my 2 1/2 yr 1J Project!!!!

It also has a new TO bearing, pilot bearing, the flywheel was resurfaced.

Please help!

I don't see any binding in the clutch system. What else could it be?!?!?!

 

[OneJArpus]

Could a bad machine job on the FW mess up the trans like this?

 

[WhtMa71]

It's not likely that could do it. Usually the backstep is messed up and the clutch will just slip but it will still operate. I suppose the machine shop could really do something wrong but they'd have to mess up pretty bad.

If you have checked everything per the tsrm and it all seems normal, im guessing there's a problem with your clutch assembly. Are you sure you assembled the release hub/washers/clips correctly?

 

[OneJArpus]

It's not likely that could do it. Usually the backstep is messed up and the clutch will just slip but it will still operate. I suppose the machine shop could really do something wrong but they'd have to mess up pretty bad.

If you have checked everything per the tsrm and it all seems normal, im guessing there's a problem with your clutch assembly. Are you sure you assembled the release hub/washers/clips correctly?

I'm 99.99% sure that the clutch assembly was done correctly. I had the TSRM & a spare PP & Assy in hand for when i put the assy together. Could I have installed the fork incorrectly causing it to operate but not fully?

 

[WhtMa71]

Im not sure, can't the fork only go in one way? It's easy to take out and see though.

 

[OneJArpus]

ok, i looked at the TSRM again. I came across this section. Now i know i followed the instruction step by step but i found this little hint. Could this prevent the entire system from operating properly?

 

[OneJArpus]

bump, need help!

 

[OneJArpus]

found my problem thanks for all your help.

Problem is the FW, someone mentioned that if the measurements are out of wack that it would put the PP on full duty not allowing the clutch to come off of it. I am going to inspect everything else in the process.

Please close thread

 

[zurud]

What's wrong with your flywheel. The same thing happen to me, but the supplier give me the wrong disc. One box, right pp wrong disc.

 

[OneJArpus]

What's wrong with your flywheel. The same thing happen to me, but the supplier give me the wrong disc. One box, right pp wrong disc.

I'm not actually 100% sure, what happened was that my flywheel was resurfaced flat by accident but the dummy machine shop.

I went back with a quote for a new flywheel. They said they will check if it was within spec still and then have another machine shop double check.

When i got back it was resurfaced correctly with the step in it. But i assumed that the material taken off the first time messed it all up.

My friend said that it could be that but highly unlikely cause the clutch isn't disengaging at all. So we figure the fork isn't installed correctly but I haven't had a chance to go under the car to double check cause its been cold out, raining, or now snowing.


Im affraid i'll have to rip out the trans again but it looks like i might have to do this