Ran Into Trouble Replacing Clutch

[burnoutboy]

So my buddy has a ED hatch with a DOHC ZC in it. Transmission is unknown. It is however a 21 spline cable tranny with no intermediate shaft, just the two main axles.
So we originally ordered a clutch/PP/flywheel for a 91 civic DX but alas they sent us a 20 spline friction disc. So we ordered a 21 spline disc. Last night we got back to work. Had a hell of a time getting the pressure plate and flywheel unbolted but 1/8 of a can of PB Blaster and a 3ft breaker bar later we were in business.
We got the new flywheel on and bolted it to 75ft/lbs put the friction disc in with the clutch guide tool holding it in place. Then we lined up the pressure plate and bolted it up to 19 ft/lbs .
With everything bolted up the friction disc will not spin free of the flywheel and it's all lined up perfect so we figure we're cool. We get the tranny all bolted up, no issues getting it lined up with the friction disc.
Here's Where the problem starts...
When we hook up the cable the clutch has no resistance until well past the full adjustment. When we removed the trans to see what was up we noticed the fingers on the pressure plate are parallel to the friction disc. They sit approx 1/2" from the surface of the friction disc. Inspecting the old one reveals the fingers angle out and in the center the are 3/4" from the friction disc.
We're thinking this may be what is causing the lack of adjustment there is nothing for the throwout bearing to make contact with. I have a new OEM replacement pressure plate (technically I have 3 LOL) but before we pull his and replace it we want to see if you guys think this is likely the problem.

If it means anything they also sent us the wrong throwout bearing. Basically they are the worst clutch sellers on ebay LOL. He got the wrong friction disc, the wrong throwout bearing, and quite possibly the wrong pressure plate. Not only that but the title said

EXEDY New clutch, pressure plate, and 16LB EXEDY flywheel!!
Well he didnt read it closely and didnt realize the flywheel was the only thing that was actually exedy.

[deddth]

well bob-san, my bet is that the only thing worth keeping is the flywheel.

my bet (like yours, possibly) is that both pp and clutch are wrong.

[burnoutboy]

well bob-san, my bet is that the only thing worth keeping is the flywheel.

my bet (like yours, possibly) is that both pp and clutch are wrong.


old clutch was wrong, new clutch is right. Just learned that the fingers on the PP are supposed to move intoward the disc as the PP is bolted down and pressure is applied to the inside of the PP by the disc itself. SO likely the PP is fine.

NOw the question is whats wrong with the way the bearing is installed. I think thats where the fuck up is.

[J.W. Racing]

I had a similar issue before, and it was the throwout bearing.I cant say for sure its your issue.
But I can verify when you tighten the pp down the fingers level out slightly with the clutch disc.

[burnoutboy]

It's got to be the way I'm installing the new TOB. There's almost no return pressure on the TOB spring. I dont think thats right. I'm pretty sure when you have it installed right there's a decent amount of pull for it to return to it's normal position from just the spring alone.

[J.W. Racing]

The spring should be fairly tight.I have a hard time getting them on sometimes with my hook tool.

[burnoutboy]

Actually it's the clutch release bearing, the clutch release fork, or the clutch release bearing return spring that I think is installed wrong. I dont know where I got throw out bearing from. I'm retarded.:D

[deddth]

clutch release bearing spring. that's my bet.



keep us posted.

[burnoutboy]

Everthing bolted up to the flywheel
http://i67.photobucket.com/albums/h311/cjwiv/IMG00352.jpg

http://i67.photobucket.com/albums/h311/cjwiv/IMG00353.jpg


The clutch release bearing sitting on it's own
http://i67.photobucket.com/albums/h311/cjwiv/IMG00354.jpg

Release Bearing with me pulling the release fork lever up
http://i67.photobucket.com/albums/h311/cjwiv/IMG00355.jpg

[deddth]

hm. so if i understand by your pics, everything should be ok and in proper working order. but it's not.

i wish i can be of more help.

[burnoutboy]

Is the clutch release fork installed facing the proper direction?

[deddth]

may i suggest installing it the other way and see what happens?

[burnoutboy]

I checked the parts diagram, the fork is correct. Is it possible the flywheel is installed backwards?

[deddth]

well, since everything seems ok, i would check if the flywheel is installed on its correct side.

[deddth]

i rechecked your posts, and that could be the culprit: flywheel could have been installed backwards. i hope that is, if not, idk man.

[deddth]

updates, bob?

[burnoutboy]

Well flywheel only mounts to PP one way according to Mr. Bone. So since everything is good and tight to eachother with the studs through the PP all of that is good... We gave up for the night just before midnight. We have no clue what the culprit is, but in the meantime he's calling the seller and telling them he wants the new release bearing,flywheel, and PP to go with the new friction disc. They just replaced the friction disc before for a 21 spline one and said everything else should be good...

[deddth]

damn bob, what could it be?

[burnoutboy]

damn bob, what could it be?
They may have sent us the wrong flywheel as well.

[deddth]

oh damn.

talk about a fucked up sale, man.

[burnoutboy]

And now all of a sudden he cant get them on the phone. BOOOOO


OH well I'm gonna take a new PP I have over there today and sway that out. Not that I think it's the problem but hopefully we may figure out what is the problem in the process.

[J.W. Racing]

yes,enquiring minds want to know

[burnoutboy]

yes,enquiring minds want to know


Will you be on the computer between like 6 and 9 at all? That's when we'll be doing this. Any and ALL brainstorming of possible ideas is encouraged!!!!! (and needed for that matter LOL)

[burnoutboy]

So... here's where we're at. We unbolted everything to check the new parts against the ones we just took off the car. We checked the PP measurements... the same. We checked the friction disc measurements... the same. We checked the flywheel measurements... the same. I mean they were all within .06" of each other anyway. The clutch release DID NOT have this much free play when we took it off. Therefore I have to assume we're doing something wrong. The only thing I'm not sure about the way I have it in there is the clutch release pictured above. At this point I'm thinking we now have all the right new parts, but something is wrong with the way the clutch release was reassembled. It kinda seems like it only goes on together one way really. ARRRRRGGGGGGGGGGGGGG. Anybody got any suggestions of what to try at least? We're desperate at this point!!!

[deddth]

so far, what has been done. could you recap.

[J.W. Racing]

Is the fork bent maybe? how about the ball and clip for the fork,whats that look like.

[burnoutboy]

The ball and clip? Dunno what that is, gotta elaborate. But I think we're dumb. We've been hooking it up with out the trans mounted to all of the chassis mounts, just bolted to the engine. I think once the bracket is raised with the trans it'll work out. I still think he needs a new cable and he agreed to buy one ASAP, but he's a over the shoulder reading broke ass Jew.

[burnoutboy]

Yeah so we got it all bolted up and back together and there's still like 3" of freeplay in the clutch release arm...



FUCKING BOOOO!

[deddth]

damn, bob.

plans for today?

[burnoutboy]

damn, bob.

plans for today?


Working 9-9 today and 9-6 tomorrow. BigTuna is coming over on Sunday with a fresh clutch cable to see if the three of us cant figure this shit out.

[J.W. Racing]

Working 9-9 today and 9-6 tomorrow. BigTuna is coming over on Sunday with a fresh clutch cable to see if the three of us cant figure this shit out.
Teleport me over.

[burnoutboy]

Teleport me over.

Sounds like a plan. Beaming up now.