'96 6-Speed Cluth Issue (please help the newbie)

[rocco_77]

Thanks in advance for any help...

I just replaced the cluth. I bought the parts from SLP Performance... Steel Billet flywheel, new pressure plate and throwout bearing assembly, new clutch disk, and replaced the master and slave with a kit from GM. The only part not replaced was the fork and pivot. All parts were thoroughly cleaned before install... All parts torqued to specs.

I have a tough time getting into first gear from a stop. It shifts fine when I'm moving... Can't get into reverse without grinding... I turn the car off to get into reverse so I don't damage the tranny... I've been driving the car like this for a couple weeks, because it's my daily driver. When in first at a stop with clutch pedal down, I feel the disk almost engaging, and the car moves forward ever so slightly... So I know I'm not getting full disengagement. Also, when at idle in neutral with my foot off the clutch, I get a pretty good amount of vibration in the pedal, and a ticking noise... And actually, the pedal vibrates all the time, just that the vibration speeds up as I go faster. I can pump the cluch a couple times and it goes into first easier, but reverse is still a problem, and the vibration is kinda bad... something is obviously wrong, and I would very much appreciate some input...

I plan on tearing it down again next weekend... I also ordered a replacement fork and pivot from GM...

Thank you.

rocco_77

[Philo]

Did you replace the pilot bearing? Sometimes they fall out when the transmission is removed. If the transmission front shaft can move around, the clutch will be able to contact the pressure plate slightly (on one edge) even with the clutch pedal fully depressed.

[rocco_77]

Thanks for the reply...

Yes, I did replace the pilot bearing.. (forgot to mention that)

The old one was dust, but the race was still in the end of the crank... So we got the old race out, and put in the new bearing...

The new bearing may be part of the problem, but I won't know until this weekend when I pull the tranny out again.... This sucks.....

Anyone else have any ideas?

[Philo]

Originally Posted by Philo

Did you replace the pilot bearing? Sometimes they fall out when the transmission is removed. If the transmission front shaft can move around, the clutch will be able to contact the pressure plate slightly (on one edge) even with the clutch pedal fully depressed.

The next thing I would check then is to make sure the clutch is free from the flywheel when the clutch pedal is depressed. I have a feeling there is some drag there. If you put the trans in neutral, and (have someone) depress the clutch pedal, you should be able to turn the clutch plate (the friction material) with your fingers through the inspection plate (I think newer cars still have the plate).

Also, not sure, but maybe air in the hydraulic system could cause the clutch to not be fully released.

[rocco_77]

Hey Philo... Thanks for posting again....

Actually, the hydraulic system was the first thing I suspected, and the only part I could replace again without removing the tranny... So I'm already on my second Master and Slave kit from GM (the kit comes as one piece: resevior, master cylinder to the clutch pedal, and slave cylinder mounted on the bell-housing.... pre-bled in a bag, and there is no bleeder valve on the unit) So I don't think the hydraulics are the problem...

I don't think the bell-housing has an inspection plate, but I will check...

Another thing I thought was maybe somehow when remounting the tranny that we bent the clutch disk.... The tranny went in real smooth, so I'm not sure about that... Another thing is the throwout bearing....

And what would you make of the pedal vibration I described?

BTW, yesterday I picked up a new fork and pivot... I'm also suspect that the fork could be bent... It's the only part I didn't replace...

This is very frustrating...

[Philo]

Originally Posted by rocco_77

Hey Philo... Thanks for posting again....

Actually, the hydraulic system was the first thing I suspected, and the only part I could replace again without removing the tranny... So I'm already on my second Master and Slave kit from GM (the kit comes as one piece: resevior, master cylinder to the clutch pedal, and slave cylinder mounted on the bell-housing.... pre-bled in a bag, and there is no bleeder valve on the unit) So I don't think the hydraulics are the problem...

I don't think the bell-housing has an inspection plate, but I will check...

Another thing I thought was maybe somehow when remounting the tranny that we bent the clutch disk.... The tranny went in real smooth, so I'm not sure about that... Another thing is the throwout bearing....

And what would you make of the pedal vibration I described?

BTW, yesterday I picked up a new fork and pivot... I'm also suspect that the fork could be bent... It's the only part I didn't replace...

This is very frustrating...

It is strange allright. Of course, there is always the chance that a defective part (warped pressure plate for instance) even though they are new is the problem. Let us know what you find. Because the clutch pedal vibrates, I guess I would replace the fork (the last old piece) and then if it did not fix it, take it all apart again and check everything.

The big problem is that without a fix, you are going to destroy the transmission after a while.

I am a really old guy, and when I had a '63 Cat, it took out second gear twice before I found the pilot bearing was bad. After replacing the bearing I drove it many more miles with no problems.

[rocco_77]

Ok Philo... I'm already taking the car apart this weekend... then you want me to put it back together and then possibly take it appart again?! Are you kidding me! LOL... I don't think so... If I can't figure out what's wrong when I have it apart this weekend... this sucker is going to AA *beep, beep* MCO... believe it.

I have already decided that this is the last time I'm replacing the clutch on this car myself... I'm going to let someone else hassle with it when I hit 200K miles..

So that's the plan... tear it down, replace the fork and the pivot, check the bearing, and inspect the other parts for defects. Do you think the pedal vibration could be coming from a bad throwout bearing AND a bent fork?

The tranny is fine right now... I've been up-shifting without using the clutch this week, and stopped down shifting when rolling to a stop.

If I don't get a reply from you or someone else tomorrow, then I will post on Monday with our findings.

Thanks again for your attention here and your suggestions.