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Old 08-31-2019, 11:18 PM   #1
SlayZombi
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Question New Clutch, Possible Issues?

Had someone do some transmission work for me today. Pretty reputable guy, got around via word of mouth and I took him up on his quoted price for full clutch kit replacement and new flywheel, new master & slave cylinder, and fluid flush. The issue I am having now is that unless I REALLY fully depress the clutch (no I don't mean just bottom out, I mean pretty much past bottoming out), it wont go into gear. I have to struggle to get it in any gear with the car on (off is fine). It doesn't grind or anything, it just wont get into gear. I told the guy about it and he said that the new clutch needs to wear in. Is there truth to this or should I get it checked out before my clutch is eaten away? I've driven a total of about 30 miles on it.

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Old 08-31-2019, 11:27 PM   #2
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Default Re: New Clutch, Possible Issues?

That is BS. The clutch should work properly the very first time it is put to use.

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Old 09-01-2019, 01:04 AM   #3
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Default Re: New Clutch, Possible Issues?

Quote:
Originally Posted by billr View Post
That is BS. The clutch should work properly the very first time it is put to use.
Yeah I'm a bit skeptical...

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Old 09-01-2019, 08:57 AM   #4
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Default Re: New Clutch, Possible Issues?

Quote:
Originally Posted by billr View Post
That is BS. The clutch should work properly the very first time it is put to use.

Yes, I have installed my clutches, not on Saturns but other cars/trucks first time, he missed something.

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Old 09-01-2019, 09:12 AM   #5
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Default Re: New Clutch, Possible Issues?

The most common goof on doing the clutch is not properly installing the slave cylinder. Usually with a used unit the rod that goes inside the transmission falls down into the bell housing but it could just be misaligned on the bar that physically actuates the clutch.

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Old 09-01-2019, 09:23 AM   #6
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Default Re: New Clutch, Possible Issues?

I also call BS. Something is wrong either with the parts or assembly.

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Old 09-01-2019, 09:25 AM   #7
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Default Re: New Clutch, Possible Issues?

Quote:
Originally Posted by SlayZombi View Post
... new master & slave cylinder, and fluid flush.
My first thought is air in the line for the master/slave cylinder. Iím with fetchitfido in that the master/salve assembly is not installed correctly. The slave cylinder needs to be lined up correctly and have a solid push and twist to get it into place and can be a bit tricky. Also check the fluid level and ask him what kind, it needs to be a DOT-3 fluid.

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Old 09-01-2019, 12:38 PM   #8
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Default Re: New Clutch, Possible Issues?

The OP said the master and slave are new, too.

But, there was also a "fluid flush". That may be a clue. If the master and slave were replaced, in the normal manner, there would be nothing to flush...

First step would be the "wire test" to determine if the fork throw is adequate.

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Old 09-01-2019, 01:21 PM   #9
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Default Re: New Clutch, Possible Issues?

I was wondering what fluid was flushed - hydraulics or transmission. Not that you can really do either. If he tried to flush the fluid on new, sealed hydraulics that already have fluid he may have messed it up.

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Old 09-01-2019, 02:35 PM   #10
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Default Re: New Clutch, Possible Issues?

Quote:
Originally Posted by billr View Post
The OP said the master and slave are new, too.

But, there was also a "fluid flush". That may be a clue. If the master and slave were replaced, in the normal manner, there would be nothing to flush...

First step would be the "wire test" to determine if the fork throw is adequate.
The unit came as one sealed assembly so I don't think that was flushed out. I told him to flush the transmission fluid, which was done because the dipstick is returning a nice red coloring. I did kind of mess around a bit with the slave cylinder last night and it seems to be able to rotate a couple degrees even without disassembling something. I'm going to give it a shot and try to reassemble it.

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Old 09-01-2019, 04:44 PM   #11
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Default Re: New Clutch, Possible Issues?

UPDATE: I reinstalled the slave cylinder by using a picture to guide me to where it needs to be installed. I got it lined up perfectly and locked it in place. It's solidly in there. Started it up and tried again. It's no different. It's not totally unlivable but requires me to depress the clutch pedal to its maximum distance to even get it in gear. It also engages right off the floor. Like I mean maybe an 1/8th - 1/4th of an inch.

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Old 09-01-2019, 05:00 PM   #12
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Default Re: New Clutch, Possible Issues?

Does it feel even the least bit soft? If so, it's probably air bound and needs thorough purging. The first thing to do is to measure travel. It will take two people - one to depress the clutch. Richpin06A on Youtube has a video on exactly how to do this.

https://www.youtube.com/watch?v=ZL-FZ7bT4_A

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Old 09-01-2019, 05:18 PM   #13
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Default Re: New Clutch, Possible Issues?

Quote:
Originally Posted by S-forever View Post
Does it feel even the least bit soft? If so, it's probably air bound and needs thorough purging. The first thing to do is to measure travel. It will take two people - one to depress the clutch. Richpin06A on Youtube has a video on exactly how to do this.

https://www.youtube.com/watch?v=ZL-FZ7bT4_A
Nope, it feels great and there were no leaks or anything of the sort seen when I took the slave cylinder out.

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Old 09-01-2019, 06:37 PM   #14
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Default Re: New Clutch, Possible Issues?

Need to actually measure the clutch fork travel as the next step in diagnosis. Since clutch, flywheel, and master/slave hydraulics are new, and the main suspect currently is the hydraulics that may have air in the line, it requires testing it to either confirm faulty unit or rule it out. Follow the link S-forever gave you to measure the clutch fork travel and report back.

Side question: what brand of hydraulics did the mechanic use?

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Old 09-02-2019, 09:49 AM   #15
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Default Re: New Clutch, Possible Issues?

Do you know what brand clutch he used? Really only one brand worth installing. Luk. There may be a slight difference in the plate causing the issue.

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Old 09-02-2019, 12:17 PM   #16
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Default Re: New Clutch, Possible Issues?

Aren't there even two versions of the LUK, one that needs to be "wound up" at installation and one that just installs with no fussing? Really, though, until the wire test is done, there is little point in guessing further.

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Old 09-02-2019, 12:31 PM   #17
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Default Re: New Clutch, Possible Issues?

Out of town right now. I'll be back with another update after I try the wire test later today. To answer the other questions about what brand of parts I used, I used the Exedy clutch kit and a LUK hydraulic kit.

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Old 09-02-2019, 09:42 PM   #18
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Default Re: New Clutch, Possible Issues?

UPDATE: So I tried to do the whole wire thing and it wasn't going so well. None of my homemade contraptions were accurate enough so I just went ahead and followed this procedure to bleed it anyway: http://www.saturnfans.com/forums/sho...d.php?t=123791

No bubbles came out no matter how much I moved the hardlines around. I guess that's a good thing... I put it all back together. I guess at this point I'll just wait it out. It seems to be getting easier to **** so maybe what that guy said had some merit.

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Old 09-03-2019, 01:06 PM   #19
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Default Re: New Clutch, Possible Issues?

Are you sure they put the correct generation clutch in there?

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Old 09-03-2019, 01:24 PM   #20
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Default Re: New Clutch, Possible Issues?

Quote:
Originally Posted by SlayZombi View Post
UPDATE: So I tried to do the whole wire thing and it wasn't going so well. None of my homemade contraptions were accurate enough so I just went ahead and followed this procedure to bleed it anyway: http://www.saturnfans.com/forums/sho...d.php?t=123791

No bubbles came out no matter how much I moved the hardlines around. I guess that's a good thing... I put it all back together. I guess at this point I'll just wait it out. It seems to be getting easier to **** so maybe what that guy said had some merit.
I think he's trying to stall you. I did my clutch and it worked great the moment I got the car back on the ground. But these types of issues are common with bargain clutch kits.

-Robert

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