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Old 06-08-2021, 02:45 PM   #1
Marz
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1995 SC2
Default New clutch installed now no shift...

Hi Everyone!

It's been a while since I've post on here but it's been a while since my Saturn has had a running engine in it!

I finally finished my junk yard engine swap last weekend; and managed to fire it up. After a few minutes it started running nicely BUT it would shift into gear...

Since I had to swap the manual transmission from the old engine to the JY one I went ahead and put in a new LUK 04-115 (#from memory) clutch in.

I can shift into gear with the engine off with and without pressing the clutch pedal, but with then engine running, it's a no go.

The clutch pedal feels really soft; so I tried bleeding but saw no bubbles in the reservoir while working the slave piston; I drained and refilled the brake fluid as it was very red?/rusty lucking but still no shifting...

So I bought a new hydraulic clutch assembly (LUK brand) and installed it last night. Pressed on the clutch pedal and it was much firmer then my old one! Then there was a pop! And the pedal felt soft again... like the old one...

I pulled the slave out of the bell housing to check if the rod had come off the fork or had not been installed straight enough, I found the end of the slave had burst open, a black cylinder covered in grease a bit of spring hung out the end... I still have to fish the rod, rubber seal and who knows what else from the bottom of the bell housing.

Has anyone had anything like this happen? Or heard of such a thing? I've read I think all of the "New clutch No shift" threads that I could find; the only ones that give a clear this fixed the no shift are one where the hydraulics are the culprit.

If no else can point me in another direction, I think I'll have to pull the bell housing off and re-install the clutch to see if I did something wrong.
...
1995 SC2 Purchased with 119985 miles
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Old 06-08-2021, 11:52 PM   #2
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Default Re: New clutch installed now no shift...

With new hydraulics there should be a trio of oversized zip-ties going from the center of the rod to the slave. Leave those installed when you put the slave in, they break upon first use and properly place the rod in the clutch fork.

While I never had an issue with it, getting the clutch fork snapped onto the retention ball can be a chore and if missed...can lead to a useless clutch. The good hydraulics used to be in the $150 range, though I know someone (Dorman?) came out with a $50ish set. I expect the QC on the $50ish sets to be as useless as a clutch after it's had 200 newbies use it.
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Old 06-12-2021, 01:12 PM   #3
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1995 SW2
Default Re: New clutch installed now no shift...

Could have installed the friction disc backwards.
...
1994 Sl2 5spd First Car, Stock: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd: Retired Daily, Not Stock: 192,000
1998 Sl2 5spd: Family Car, Stock :135,000
1995 SW2 4spd: Daily, Stock: 91,000
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Old 06-17-2021, 11:42 PM   #4
Marz
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1995 SC2
Default Re: New clutch installed now no shift...

Well, it took my most of the day but it's all fixed!

I pulled the transmission; checked the clutch and clutch plate they looked fine.

When I inspected the fork and clutch bearing, the pivot clip was askew and the plastic base had fallen off...

I re-centered the clip on the fork, put the plastic base back on the button and pushed the fork/clip onto the button until it "CLICKED" into place. Then manually operated the fork/clutch bearing and it pivoted correctly on the pivot button.

It was so much fun to drive! It's been a work in progress for 2-1/2 years when the original engine died.
...
1995 SC2 Purchased with 119985 miles
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Old 06-18-2021, 04:03 PM   #5
SC2Sick
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1997 SC2
1995 SW2
Default Re: New clutch installed now no shift...

Awesome. I've had issues before too doing these so I have a sort of checklist as I'm putting them back together that's composed of all the ways I've messed up the installs. Glad you got it going again.
...
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Old 06-19-2021, 09:37 PM   #6
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Default Re: New clutch installed now no shift...

Glad she's back on the road!
...
1994 Sl2 5spd First Car, Stock: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd: Retired Daily, Not Stock: 192,000
1998 Sl2 5spd: Family Car, Stock :135,000
1995 SW2 4spd: Daily, Stock: 91,000
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