Help, clutch wont disengage properly

**nuk1ear** · 01-03-2011, 03:38 PM

Hi, have an AE92 with silvertop 4age in it. Changed the clutch/driveshafts about 2 weeks ago. When we got it all back together the clutch pedal wasnt doing anything. Found that the master cylinder just decided to die (spring snapped inside). Got a new master and it all worked well. After about a week now the clutch pedal isnt disengaging the clutch properly, very hard to get into 1st and reverse from standing and sometimes when in 1st and you release the brake (clutch fully in) the clutch will be catching so much that the car will move.

I have tried bleeding the clutch through about 5 times now, no air in the system, now its worse. Cant even get the clutch to disengage AT ALL. I can start the car in gear, release the brake and the car will move easily. Could the release fork have cracked maybe? How can i test the slave to see if its leaking? It seems to be consistantly moving forward the same distance each time, about an inch roughly.

There is an adjustment nut behind the clutch pedal, its already fully out to give the clutch maximum movement. What the hell is happening here?

**wilbo666** · 01-03-2011, 10:51 PM

Can you get someone else to check to see if the slave cyl is moving when you press the pedal?

Another thing I like to check is that if you crack/loosen the output on master cyl and press the pedal that fluid comes out

Originally Posted by nuk1ear

There is an adjustment nut behind the clutch pedal, its already fully out to give the clutch maximum movement. What the hell is happening here?

This might actually be a problem, if the cyl can't retract enough it might not be clearing the port that allows fluid in from the reservoir ...

Cheers
Wilbo

**yotamotion** · 01-03-2011, 10:59 PM

Another thing you can do to check if the slave is leaking is pull the rubber boot off the slave and see if it is wet with fluid inside. Sounds obvious but just a suggestion just in case you didnt know

**jazz9** · 02-03-2011, 12:46 AM

How are you bleeding the clutch?

Check the gearbox bolts to the block are tight. This can cause the problems you speak of.

I would replace he slave also as it is a cheap part.

Glen

**nuk1ear** · 02-03-2011, 01:14 AM

The slave piston moves out about an inch. It seems to actuate fine to me, i moved to boot back and there is some gunk there, but its not excessively wet to me. Maybe replace it anyways. The clutch could be dud, springs not releasing the tension properly? But also what if the fork was cracked and the crack has slowly become bigger, this could result in my issues too right?

Im bleeding the clutch by having my mate press the pedal, opening the valve to let the fluid out, compressing the piston fully in, closing the valve. Release the pedal, pump it a couple of times and hold it, open valve, compress piston, close valve, refill reservior etc etc.

The piston seems to move out far enough (im no expert) and it is consistantly moves to the same position. The strange thing is this. Yesterday i took a video of the piston cause i wanted to check if it was losing pressue when the clutch was fully pressed. Now i compare how far the piston moves today after the bleed to yesterday before bleeding and it looks like it moves exactly the same distance out. But not the car is undriveable and no gear is selectable where as yesterday it was possible to get it into gear.......

**pandaah** · 02-03-2011, 01:42 AM

sounds like you need to adjust freeplay in your clutch pedal now you have a new clutch actually..

step 1- make sure the clutch is bled properly
step 2- move your clutch pedal and look at the pushrod that pushes into the master cylinder, you may need to crack the lock nut off and decrease the length of the rod by "screwing" it INTO the clutch pedal a few mm... lock the nut and try that..

its either that or your having problems with your throw out bearing, you havent broken or adjusted the clutch fork pivot ball?

**nuk1ear** · 02-03-2011, 02:01 PM

tried the above already, the nut is fully out towards the pedal. Pretty sure im gonna have to get the friggin box off again this weekend. Seems that either the thrust bearing isnt sitting right, fork is broken or the pressure place is faulty. Ill go over the simple things again this weekend.

**allencr** · 02-03-2011, 03:10 PM

Originally Posted by nuk1ear

Seems that either the thrust bearing isnt sitting right, fork is broken or the pressure place is faulty.

The bearing is very unlikely so those are the only chances except for the disk coming apart.
Can you look in through the fork's boot to see if the bearing is moving in proportion to the slave? Whatever you see doesn't really matter, its still gotta come apart. Good luck.

**1gjet** · 02-03-2011, 10:11 PM

Might sound odd, but when i changed clutch, the pin on the slave was too short and the cylinder was popping out of the housing, maybe you need a longer slave pin.

**pandaah** · 02-03-2011, 11:15 PM

Originally Posted by nuk1ear

tried the above already, the nut is fully out towards the pedal. Pretty sure im gonna have to get the friggin box off again this weekend. Seems that either the thrust bearing isnt sitting right, fork is broken or the pressure place is faulty. Ill go over the simple things again this weekend.

can you take a photo?.. because it doesnt sound right and i think that may be your problem.. if the car is driving in gear when its in gear and doesnt make crook noises, and your slave is moving about an inch and everything is bled properly theres only a few problems that are pritty uncommon..

just trying to help, up to you..