*HELP* [TA23] New Excedy Clutch Won't Dissengage

[RAAAH23]

Hi guys need some help pretty badly.

Ive installed my new HD excedy clutch kit (part no. TYK-6115HD). Ive pulled everything back out and it was installed perfectly. The problem is when the clutch pedal is pressed down the clutch wont dissengage and its practically not driveable sure it makes a difference between clutch out and clutch in but its still crunching gears. I also cant get reverse at all when the car is on.


Has anyone installed a HD Excedy Clutch Kit into a TA23 possibly a TA22 (same running gear) and rectified this problem?


Ive bled the hydraulics 3 times and maxed the adjustment out on both slave and pedal. It seems there isnt enough travel for the clutch to be fully dissengaged. Ive compared the OEM clutch (which still had TEQ printed on them) to the new excedy kit there is a difference between the two. The pressure plate on the excedy kit is higher than that of the OEM plate.

Now would it make sense to say that this is incorrect? Shouldn't the pressure plate be lower than that of the OEM pressure assembly, as the new clutch is thicker as its a heavy duty with abit more meat on it? If this is true the plate isnt coming back away from the flywheel enough and still letting the clutch disk rub on both flywheel and pressure plate.


I had my mechanic look at it and hes not a toyota expert or anything but he said my gearbox was a half alloy half steel combo, would this be true and if it is would that be my problem (ive got a different box)?

Ill grab the part numbers on the stock oem part and could someone please vertify if it matches a TA22 parts book? As thats which car the excedy kit was referenced against (No TA23 on their system).

Thanks soo much for any help you have to offer, hopefully this does not hinder my attendance at the Classic Celica Appreciation Day my nuts are crossed =\

If you know what the problem might be give me a call (O438 484 176) as i wont be on the computer.. Once again thank you.

[SilverRA23]

Are the hydraulics OK? No leaks at the slave cylinder for instance?

Just a suggestion..

[RAAAH23]

Yes, everything is working fine with the hydraulics. The slave cylinder is fine as is the master. It moves the clutch fork all fine and dandy but i dont think it moves it enough for the pressure plate to dissengauge.

Its extremly frustrating and if i cant get it fixed by saturday night the old shithouse slipping clutch is going back in.

[pandaah]

did you have the flywheel machined?.. they might have done it wrong, either taking too much meat off or maching the lip incorrectly..

also, have you checked for pedal freeplay?.. may have to adjust the rod from the pedal to the master cylinder

[JP]

you sure the plate's not in backwards? I've seen this more than a few times when it's installed with the high-side facing the flywheel

[o_man_ra23]

Can you give a photo of the gearbox??

Is there an adjustment on the clutch slave cylinder rod?? The RA23/28 had an adjustment on thiers which you could change. If not, can you extend the clutch slave cylinder rod??

What is the difference in throwout bearing between the original and Excedy version?? Any or none??

[croatianator]

a bit off topic, but how much did you pay for the clutch kit?

thanks!

[RAAAH23]

did you have the flywheel machined?.. they might have done it wrong, either taking too much meat off or maching the lip incorrectly..

also, have you checked for pedal freeplay?.. may have to adjust the rod from the pedal to the master cylinder

Yes flywheel was machined, dad has used them a couple of times and theyve been reliable. Ill take it to another clutch shop to see what they have to say but time is running out fast.

That has also been adjusted to pick up the clutch from the very start give or take 4-5mm. On the pedal it feels like a perfect clutch some movement then it gets alot stronger as you push it futher down but it just seems like its afew mm shy of releasing the clutch disk.

you sure the plate's not in backwards? I've seen this more than a few times when it's installed with the high-side facing the flywheel

Yep its in properly when i pulled it out i made sure i check and it was.. thats the first thing my mechanic said to me. But i was pretty sure i installed it correctly.

Can you give a photo of the gearbox??

Is there an adjustment on the clutch slave cylinder rod?? The RA23/28 had an adjustment on thiers which you could change. If not, can you extend the clutch slave cylinder rod??

What is the difference in throwout bearing between the original and Excedy version?? Any or none??

Ill get the photo tomorrow.. Yes there is and its maxed out there is two nuts on the end of the rod. one is tapered and fits into the end of the clutch fork the other is just a locking nut. Its all the way out, anymore and id be running the risk of it popping out of the hole in the fork.

Might need that to be custom made unless there is something somewhere on some car that is an exact fit. I dont have much time to be scouring wrecking yards thou and it still might not fix the problem =\

Yes the stock thrust bearing is thicker by afew mm, im going to chuck that on and see how she goes.

a bit off topic, but how much did you pay for the clutch kit?

thanks!

Its fine mate, $245 comes with clutch plate pressure plate thrust bearing and some lube. I got it from bulk auto parts up here in sydney. It might be a little cheaper for you down south as the headoffice/factory is located down there. I had to get the special ordered so took a day to get it in.


Thanks alot guys, i also found this on the excedy site:

Problem:
Difficult disengagement after installation of new clutch

Symptoms:
Always check components before fitting and ensure that the retractor clip is located on top of the diaphragm. (This is the installer's responsibility).

Cause:
Cover assembly has been dropped during installation/or during transit causing damage to retractor clips. Note: the retractor clip is under the diaphragm.



http://www.exedy.com.au/EDiagnose.aspx?id=15

Ill check all that out tomorrow and any other possible causes that they list there.

[o_man_ra23]

A couple of mm on the throwout bearing is a big difference, however that retractor clip looks like it might be your issue. I would try the retractor clip before swapping out the bearing.

Also, did you change your spigot bearing??

[RAAAH23]

A couple of mm on the throwout bearing is a big difference, however that retractor clip looks like it might be your issue. I would try the retractor clip before swapping out the bearing.

Also, did you change your spigot bearing??

Yes it does, the mechanic changed the thrsut/throwout bearing back to the original, it did make a difference but it was still crunching gears. Spigot bearing has been changed, this was done when the flywheel was machined.

Retractor clips on all there openings were in the correct positions.

Both the mechanic and the part bloke agree that the pressure plate is sitting to high compared to the stock pressure plate. So im getting just a stocko OEM replacement and hopefully that will work which i dont see why it wouldnt. \

Both parties have said the OEM is more than enough to handle anything the old 2T can thow at it. The only reason i went with the heavy duty was to get a longer life out of it. But unsurprisingly both the mechanic and parts guy said if you want it to last long dont drive like a hoon

Clutch should be here by 3pm and ill have it in either tonight or tomorrow.


Thanks Everyone for their input +rep

On another note my venitians should be coming in this arvo and my good/untorn drivers seat will also be going in before Sunday.

[Cuzzo]

Sorry i didnt read the whole thread.

Is your master ok? Moving correctly?

[RAAAH23]

Yep all hydraulics were working fine.. Both master and slave were operating correctly.

[allencr]

Both the mechanic and the part bloke agree that the pressure plate is sitting to high compared to the stock pressure plate.

I can't figure out what 'to high' is, like the PP spring's fingers height when installed, are close to the PP cover when they should be down towards the flywheel?
If they aren't very low, toward the flywheel, but almost touching the cover, then it won't take much wear of the flywheel & disk & PP face, for them to start making contact with the cover and the clutch won't be engaged completely.
Different manufacturers & models will sit a little differently, the slave & release bearing have enough travel to take care of any reasonable differences, but yours looks like a parts mismatch when it was assembled.

[RAAAH23]

I dont know if this will help you.. but thats the PP assembly the top of the drawing is the flywheel side the bottom is gearbox side.

[w810sc]

the clutch fork to slave cylinder push rod should have 1mm of play, there should also be an adjusting nut on the clutch master cylinder.
Even when you lift the gear stick to put it in reverse does it go in?