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Old 03-29-2010, 10:17 PM
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clutch problems need some ideas

This is my sons 96 acura, manual 5 speed,135,000 miles. I hope someone can help, it's got me stumped....started out being harder and harder to shift gears, throw out bearing was making noise, so he decided to replace the clutch/bearing/fly wheel/flex plate, the whole bit. after assembly it sounded much better, BUT it did not shift any better than before, the clutch was not releasing properly, got worse as time went on , now with the clutch pedal all the way to the floor and in gear, if ya go to start it, it tries to take off, clutch not releasing, being a hydraulic clutch, we replaced master/and slave and fluid (again) bleed it (again) and absolutely no difference....Pulled the tranny (again) I inspected it closely and found nothing unusual....This was a expensive clutch kit...Installed properly...The problem has been with the car for a long time, even before the new clutch,...before we took it apart for the second time i watch the clutch fork while my son depressed the pedal and it responded and move very well, How much does a flex plate have to move to release the clutch, it moves at least 1/2" now, if it moved back much more it will bottom out on the bell housing....any ideas???????















9again)

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Old 03-30-2010, 10:35 AM
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Quote:
Originally Posted by awert
This is my sons 96 acura, manual 5 speed,135,000 miles. I hope someone can help, it's got me stumped....started out being harder and harder to shift gears, throw out bearing was making noise, so he decided to replace the clutch/bearing/fly wheel/flex plate, the whole bit. after assembly it sounded much better, BUT it did not shift any better than before, the clutch was not releasing properly, got worse as time went on , now with the clutch pedal all the way to the floor and in gear, if ya go to start it, it tries to take off, clutch not releasing, being a hydraulic clutch, we replaced master/and slave and fluid (again) bleed it (again) and absolutely no difference....Pulled the tranny (again) I inspected it closely and found nothing unusual....This was a expensive clutch kit...Installed properly...The problem has been with the car for a long time, even before the new clutch,...before we took it apart for the second time i watch the clutch fork while my son depressed the pedal and it responded and move very well, How much does a flex plate have to move to release the clutch, it moves at least 1/2" now, if it moved back much more it will bottom out on the bell housing....any ideas???????
9again)
hows the oil level in the trans? did you polish and re-grease the bearing retainer? how hard is the pedal to push?
is there any grinding on shifts? how many miles are on the car?
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Old 03-30-2010, 12:30 PM
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when we put it back together we filled the tranny with new oil, as stated there is 135 thous on it. the pedal feels normal, not hard but not spongy either. Grinding??? Yea, for sure, ever shift gears without putting in the clutch? I thought about the tranny itself, but i really don't think so, but could it be????? except for shifting, it goes thru all gears, never pops out....I-Da-No It's starting to piss me off.......
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Old 03-30-2010, 02:14 PM
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Hi,
I think you may need a new clutch cable, sounds as if yours has stretched, have you tried adjusting the clutch?
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Old 03-30-2010, 03:00 PM
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there is no clutch CABLE, it is hydraulic all the way, clutch pedal adj. was the first thing i tried, all the way in and all the way out, no difference..........
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Old 03-30-2010, 03:20 PM
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I knew it was hydraulic, I don't know why I put in about a cable.
Anyway, about the only thing left is the throughout bearing, do
you think there could be more then one for your car? or that
the person picking the order for you got it wrong?
Rich
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Old 03-30-2010, 04:08 PM
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I thought of that, it's a new bearing, but does look a little different than the original, but i measured a few places and they are exact. funny part is the flex plate does "FLEX" but it does not release the clutch disk fully...the disk was centered with the spline tool provided, it went back together great. but we are back to square #1...
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Old 03-30-2010, 08:22 PM
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Have someone look at the slave cylinder when you depress the clutch pedal and check it for full movement. I would be willing to bet you either have a slave cylinder going bad or the clutch master cylinder.

Vince
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Old 03-30-2010, 09:02 PM
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both master and slave are new, and bled, and i did watch the fork as the pedal was pressed, that's why the problem eats me up, i can't understand it......
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Old 03-31-2010, 04:32 AM
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is it hard to get in any gear? or just specific gears? have you tried to disconnect the shift cables and try to engage the trans manually by hand to see if theres a difference? what did you use for lube in the trans?
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Old 03-31-2010, 02:09 PM
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tell me if i'm wrong, if the clutch disengages properly, the splined input shaft of the transmission (which is attached only to the clutch disk) would not even be turning....Right???? So if i put it in 1st. depress the clutch all the way and then go to start it, it should not lunge forward....Right???? Unless of course, the clutch is not fully disengaged....Right So the problem can not be transmission related...Right???
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Old 03-31-2010, 03:11 PM
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Was the Flywheel turned? There should be a step in that flywheel. One of the first things I would check is to make sure that step is the correct measurement.
If its incorrect the clutch can do some weird stuff.
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Old 03-31-2010, 03:51 PM
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Interesting, what do ya mean "STEP" how do i know what the measurement should be??? I don't think i have the old one any more, but maybe........
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Old 03-31-2010, 04:39 PM
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Quote:
Originally Posted by awert
Interesting, what do ya mean "STEP" how do i know what the measurement should be??? I don't think i have the old one any more, but maybe........
A step is.. the surface that the disc ride's on is a slight higher than where the pressure plate sits. If the flywheel was ground on the disc surface and not the outer edge to keep the step in spec there will be problems.

I didn't see a post of the exact model of your car but for example, a 96 Integra has a .112 step in the flywheel.
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Old 03-31-2010, 05:34 PM
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Right, it is a Integra.....I will have to check that out.......
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