Problem after replacing clutch!!!

[My3rdBaby]

I've got a 91 240. Here's the story...I just picked up this car about a month ago. The transmission was going out and my clutch was slipping real bad. So I picked up another transmission and ordered the stage 1 (220 ft lbs.) RPS clutch from MVP. I also got a full SS line to go from my clutch resivour to the slave cylinder. Along w/ a new throughout bearing and oem slave cylinder. And had the flywheel resurfaced.

So I pulled the old transmission and clutch and threw all the new stuff in, no problem. The transmission shifted just fine....untill I started the car. The clutch has a real stiff feel to it and everything looked good but when I go to put it in any gear it feels like I don't have the clutch pressed. So I pull the transmission back off and go and get another one, that I know is good. And have the same results. So it's definitely not the transmission. I think maybe I have the wrong clutch so I look at the part numbers and cross reference them on MVP's site and they sent me a different clutch...the one that holds 400 ft lbs. But it is still for the Ka24de. So the only thing I can think of is either I installed the clutch plate backwards (which isn't probable b/c if you install it backwards, then it will hit the flywheel and not lay flat against it), or that the pressure plate is to much for the stock clutch system.

But neither of these sound like what it is, b/c the stock system should be strong enough to at least engage the clutch. And I even tried rev-matching and it still wouldn't go into gear. The only other thing is that I didn't use standard transmission oil, I used Royal Purple for manual trannys. But still, even if I used lawnmower oil, it would go into gear once!

So I'm hoping someone has some insight to this or can maybe point something out that I forgot or am not seeing. Any suggestions would be greatly apprieciated. I'm also going to go ahead and pull the transmission....AGAIN! And inspect the clutch and everything. I'm considering throwing the old one back in, to verify the problem is the pressure plate being to strong!

Thanks!

[My3rdBaby]

Update...

Well I dropped the transmission again and everything looked ok. I took out the 400 ft lb pressure plate and put my old one back in. I left the new clutch disk on the car. I put everything back together and it's still screwed up. If I push the clutch pedal in a little, it'll go into gear but I let out of the clutch and nothing happens! And if I push the clutch in all the way to the floor, the wheels start moving! AHHH! This is driving me crazy. I mean I could drive the car before all of this started so I don't understand why so many issues now! I'm gonna try adjusting the master cylinder but I don't know what to do! I need my car and I'm tired of pulling the damn transmission out!

Somebody's gotta know something!

[courterman08]

Someone please help this guy! I'm pretty sure I'm having the same problem he's having. (only I have a AutoZone replacement clutch instead)

[zenki_myles]

im having the same problem except i used an xtr clutch. i tried replacing my master and slave cylinder and no difference.

i did use royal purple but ya idk just htought id throw that out there cause i know thats not the problem. umm when you put your car in first gear with the clutch all the way down does the car slowly creep forward? if so i know im having the same problem as you and i think maybe i put the throwout bearing on wrong or something idk i really cant think of anything else

[courterman08]

I get locked out of gears all the time and it pisses me off. To be able to put the car into ANY gear you have to have your foot practically through the floorboards. And it grinds when shifting normally, clutch pedal all the way down.

[My3rdBaby]

Well...I fixed it. And yes, my car would roll slightly after pressing the clutch all the way in.

All I had to do was adjust my master cylinder. I pulled the transmisson 4 Fu**ing times!!! And yes, I'm embarresed...But at least now I can pull a transmission, swap a clutch and install in just 2 hours!

In case you need to know, to adjust your pedal all you have to do is look on the clutch pedal and you'll see a rod coming from the firewall. There's a nut on the rod that keeps it from moving. Loosen the nut and use some pliers to turn the rod. I'm not sure what the correct pedal freeplay is supposed to be, maybe someone who does can chime in. Hope this helps someone else!

[courterman08]

Sweet, I'm glad you figured it out. I'll try that as soon as I pull my car into the garage. (33* FTL)

[zenki_myles]

ugh well im glad to hear you fixed it but im not having the same problem as you cause i've adjusted my clutch a thousand times at the master cylinder and nothing happens

[courterman08]

Well, I adjusted mine. But I'm going to have to wait to find out if that did the trick or not. I still need to do my rear subframe bushings.

[scottydog]

Adjust the clutch pedal free play 1-3mm per the manual, so that the clutch starts to engage an inch or so in. Make sure it doesn't slip after adjustment.

Sorry you had to yank that sucker 4x. That blows dude...

[trackslut240]

hi i tried adjusting it but still have issues trying to shift gears and the car creeps forward...could it be the rps clutch system itself?? coz we have identical setups...hmmm...still my head over it...

[scottydog]

Having trouble going into gear means either the clutch isn't releasing completely, or your transmission is heading south.

Car creeps forward says the clutch is slipping. Check the to bearing fork lever, make sure it moves correctly when you depress the clutch pedal, and the retention clip on the lever is as it should be. Can you move the lever by hand? If so the to bearing is incorrect somehow, in backwards or wrong bearing. You did grease up teh bearing good yes?

[h-eater240]

yeah i was about to say, it needs to be greased up real nice, as i found out the hard way, putting it bone dry, is not pretty. and on top of that, i had put it in backwards. hell yeah. easy fix though. i'm having some major problems now though, my whole transmission..clutch combo is screwing up on me. i have a thread posted in the ka-t engine forum. Someone please read it and respond with some advice, i'm not looking forward to the track this friday. lol

[zZ Joshua Zz]

I've heard 1 1/2 inch freeplay but I'm not sure if thats true?

[low91240sx]

well i'm going to throw my two cents in but if they sent you a 400lb clutch and you put on the stock pressure plate wouldn't you need a bigger throwout bearing to engage the cluch seeing how the pressure plate and throw out bearing is designed for a 220 clutch? Thats the only thing that makes sense to me.
Modified by low91240sx at 11:51 PM 4/16/2008

[lovesSkylines]

did u try bleeding the system... sometimes when you take the slave cylinder out it develops air in the line (depending how you suspend it while working on the transmission)

very very easy to do....1 person can do it

hope it helps..