transmission problems after transmission re-install

[pacefarm]

after re-building the KA, i re-surfaced the pressure plate, flywheel and got a new kevlar clutch. also got a new throw-out bearing and pilot bushing.

here's the problem: i cant build up any clutch pressure for the clutch pedal to pop back and to successfully put the car into gear. during the engine rebuild, the clutch slave cylinder was just zip tied to one of the lines on the chassis, while the tranny was out. none of the hydraulic system was modified during the build. i have the clutch dampener lines removed, so its just a straight shot from the master cylinder via a hard line, to a braided steel line to the slave cylinder. i've bled the system at least 5 times. swapped out the master cylinder.

the pressure in the pedal is very inconsistent. sometimes i can get it to pop the pedal back, sometimes i have to hook it with my foot to bring it back. once the car is running, i go to put it in 1st, and it starts whining or screeching from the bell housing (i assume) and starts to engine starts to die out.. sometimes there's no squeeking or whining noise at all, but the engine starts to die all the same. also, its hard to get it fully into gear, there's lots of resistance.

any ideas? any help would be greatly appreciated!!!

[Irukandji]

Replace the slave cylinder and see what happens from there.

[pacefarm]

yep. new one's going on tomorrow.

the thing i'm concerned with is the squeeling noise that only sometimes is heard when the clutch is pushed in, and the immediate engine hesitation that follows...... would this happen if the pressure plate wasnt pushed in enough?

[koukimonster139]

sounds like it isnt disengaging all the way?

[pacefarm]

sounds like it isnt disengaging all the way?


i think so, because even though i pull the clutch pedal back, the engine hesitates like crazy unless i rev the crap out of it, which i dont wanna do since it hasnt been broken in yet...... :-/

[projectRDM]

T/O bearing is stuck against the pressure plate, you could have engaged it accidentally during the install.

[pacefarm]

*update*

got all 4 wheels off the ground and got under the car last night. pulled off the rubber dust boot from the clutch fork and snuck a peek inside. the throw-out bearing appears to be in at least 2 pieces... it was really hard to see, but i could see the outer part of the bearing, and what appearted to be the inner part, sitting on the input shaft, halfway inside the pressure plate opening.

how the F did this happen???

[pr240sx]

clutch fork misaligment
TO bearing binding on the tranny

[AdamP]

Are you using a multiple washers on the pivot ball? You may be generating too much leverage on the pivot pall because it is too far out, therefore pushing the TO bearing out too far when the fork is engaged.

[pacefarm]

hmm.. no, havent touched the pivot ball.. its the same as when i first installed the transmission. hopefully i'll have time tonight to tear it all down and maybe get an idea why things went wrong. i'll post some pics.