Corolla Clutch Problems

[NuGeN]

Hi,

I've just switched over a different engine and gearbox (silvertop 20v and c52) into my ae92 and I can't seem to get the clutch working. I've bled the system numerous times of air but it feels like the clutch isn't completely disengaging the engine when I fully depress it.

When I try to change gears while the engine is running it won't let me unless I force it (crunch it in). When I start the car in first with the clutch fully pressed in it feels like the starter motor pulls the car just a little bit. However when I'm already in gear I can still use the clutch to disconnect the engine.

So is there anyway to adjust the clutch pedal so that it pushes more against the pressure plate? I reckon if the floor wasn't in the way and I had more pedal travel everything would work fine.

Oh and the new clutch is a heavy duty clutch if that makes a difference.


Thanks in advance.

[ra_28]

Is the pressure plate in the right way?? How much free play is there in the fork before the clutch start to release?? Does it get better if you pump the clutch??

Cheers
Alex

[NuGeN]

The clutch was in good nick in the other car so I didn't separate the gearbox from the engine to check. *flame suit on*
So I can assume that the pressure plate is the right way around.

It doesn't make a difference if I pump the clutch.

And as for freeplay I will check that tomorrow.

Any other ideas for me to check tomorrow?

[Dale]

Did you use the slave cylinder out of the other car?

Check it for movement while someone depresses the pedal, if it's hardly moving then you have a hydraulic problem either the master cylinder or the slave cylinder.

There is an adjustment nut on the clutch pedal in the car but it's a PITA to get to and probably won't fix the problem if it's that bad.

If the slave cylinder is moving as it should be try putting a slightly longer rod in the slave cylinder and see if it makes any difference - I made one out of a cheap $2 screwdriver that happened to be the same diameter the last time I needed to do one

[NuGeN]

Yeh I used the one attached to the gearbox. I might swap over my old one if all else fails.

There is definate slave cylinder movement. I saw it move when I was bleeding the system of air.

What does the adjustment inside the car adjust?

[Dale]

The free play in the clutch pedal

[Talasas]

The in car adjustment adjusts the pedal height which does somewhat effect the lift the clutch has, a little.

I had this exact same thing happen 3 years ago and after rebuilding the slave cylinder and all the adjustments it still didn't work. It's been lying about since and I've now installed it because I had the flywheel has been machined and the clutch wore down a little.

I'm hoping it works.

[edit] got in before me, it also does adjust the free play too.

[NuGeN]

If there's less freeplay on the clutch pedal, would that give more movement at the slave cylinder side of things ?

EDIT: Just saw Talasas's post.
Answered my question.

[Talasas]

Nothing much apart from the extra lift you get from the pedal moving further, just rebuilding it helps in case it's worn.

[NuGeN]

How did you fix it 3 years ago Talasas?
Did you replace your slave cylinder with another ?

[Talasas]

It's been lying about since and I've now installed it because I had the flywheel has been machined and the clutch wore down a little.

I'm hoping it works.

I didn't, I threw the damn thing in a box and used my old pressure plate which worked fine. At the time I wrote it off as the clutch plate was just too thick for the pressure plate to lift.

[NuGeN]

Hey guys, got my clutch working.
Thanks for all your help.

It was simply a matter of adjusting the rod on the clutch pedal so you get more displacement. When I looked at the pedal on car that I got the gearbox out of it was clear that the rod needed adjusting.

[love ke70]

i was gonna say the rod. cool cool

might go see if the box in my ke70 has this adjustment on the pedal. dont think it does...
cheers, andrew

[NuGeN]

OK! the clutch is playing up again...
Exact same problem! however the rod is extended to its outer most position...
Can anybody help ???


I've only had the car running for the day and now this happens...

[oldeskewltoy]

Clutch systems are rather simple .... there are two systems interacting. The pedal is attached to hydralics - master cylinder, clutch hydralic line and a slave cylinder. The second part of the system is mechanical with a throw out arm, throw out bearing, and a pressure plate.

Since nothing has to be disassembled to check the hydralics go through this first. Do you have, or can you get access to the factory repair manual? I do not have any fwd manuals so I can't help specifically.

In my AE86 manual the troubleshooting section states the following faults....
too much freeplay - you've just done this...
slave cylinder faulty
master cylinder faulty
clutch disc out of "true"
dirty, or burred input shaft splines
pressure plate faulty

One thing I'd add to this... inspect hydralic line... make sure it isn't expanding when you have your foot on the clutch