zguy825

iTrader: (8)

Okay, so I've spent hours searching and cannot find what I am looking for so I decided to post.

I just replaced the engine in my 03' with another factory one. Pulled everything off the old engine and installed it on the new one. Fired up, no problems except the clutch wont disengage. Basically its in neutral when you start it but wont shift into any gears, like its not traveling enough. Bled out the slave cylinder, no air at all. Completely normal pedal feel, just no disengagement. I really don't feel like pulling the tranny out but I may have to. The only thing I can think of is I didn't install new bearings with the old clutch. Any thoughts? Is there a way to adjust how far the cylinder fires when the clutch is depressed?

Any help is appreciated, thanks!

winchman

"The only thing I can think of is I didn't install new bearings with the old clutch."

The only bearing what would matter in this case is the throwout bearing, which should go on the end of the clutch fork. Leaving it out would certainly keep the clutch from disengaging.

There is a way to adjust the pedal a little to get the correct free play at the top, but it's not enough to fix the situation you described.

Do a good search for the TOB around the area you were working in. If you find it, you know what you have to do.

zguy825

iTrader: (8)

Didn't find it. The flat side of the clutch disk faces the transmission right?

Zazz93

iTrader: (2)

Here ya go.

zguy825

iTrader: (8)

So interestingly I went to pull my transmission, and the dang thing is stuck. Once I get it out I will repost but it seems the input shaft is stuck on something.

winchman

The only things that come in contact with the input shaft are the pilot bearing in the end of the crankshaft and the splines in the center of the clutch disc. Both of those should slide right out.

It'll be interesting to learn what's causing both problems.

Are all the parts OEM?

Did you have any problems taking the transmission off the first time?

Are you absolutely sure you took all the bolts out?

zguy825

iTrader: (8)

Yes I am sure all of the bolts are out...certain. All parts OEM and the transmission was a little tough the first time but nothing like this. I spent 2 hours trying yesterday, its wobbling just fine and wont release. Going to try again today but man, it kind of tells me the pilot bearing may be seized to the input shaft for some reason, that or the clutch is seized to the shaft. We will see, going to grab a friend or two today and try it later.

winchman

Way back when, there was a removable cover on the bottom of the bell housing so you could loosen the bolts holding the pressure plate to the flywheel. That was really handy if the input shaft got hung up on the splines in the disc. A little bit of movement would ease the binding.

You did follow the service manual and apply lithium-based grease including molybdenum disulphide to the splines when you were putting it together, didn't you?

zguy825

iTrader: (8)

Ahhh who needs grease! No, I actually forgot to grease the spline..... my guess is that when I first installed the clutch disc I had it on backwards. When that happened the engine wouldn't meet with the transmission at all. I pulled the engine to find the clutch backwards, flipped it and re-installed it. During the first meeting of engine and transmission I'm fairly certain damage was done to the spline in the disc. Once the input shaft went through the damaged splines its not coming out/off so easy. This would explain why the clutch wont disengage and the transmission wont come off. Once I get the tranny out (Headed out of town for over a week) I will probably be filing the splines of the disc to get a smooth disengagement.

350zion

iTrader: (58)

No!

350zion

iTrader: (58)

Sorry didn't read all the posts..
But Yea first thing came to mind is u put the disk backwards.. Then u asked if the flat side faced the tranny n thats a no no...

I did that years ago in my old 1.8 Toyota corolla n burnt it..

Good that u found out wat was going on before any more damage....

zguy825

iTrader: (8)

yea, thanks for posting! Seems tough sometimes to get good info on here but I appreciate all that do!

dailydriver350Z

breathing life into an old thread! I am experiencing the same issue as the original post. Was there ever a solution to this and what was found to be wrong?

Syner

Does your pedal feel normal?

92K1500

iTrader: (1)

Friction disc was in backwards.

dailydriver350Z

Pedal feels great, drives great once rolling.

here are my symptoms-
Cold car I can get into gear but it's sticky
Warm car I can't get into gear without bashing down into second and then back into first
sitting still in a parking lot clutch fully depressed - pushing into first and second the car pulls forward
clutch depressed - grinds into 5th and then I can go into any gear I please with no effort

New Parts-
Master
Slave
throwout
Exedy Flywheel 18lbs
Exedy Stage 1 Clutch
Bled the system 3 times
installing a new flex line tomorrow (will update after)

Any Ideas would be helpful

Syner

Sounded like clutch or master to me. No sponge to the pedal?

92K1500

iTrader: (1)

Did you bench bleed the master before you installed it?

How much free play do you have in the clutch pedal at the top?

dailydriver350Z

Master was not bench bled before install. I did a gravity bleed for a while after install. Do you think I could have messed it up?

I tried a new test today... Let the shifter rest against 1st and pump the **** out of the pedal... slid in after i beat the crap outta the pedal

I'm leaning toward the master as well now

92K1500

iTrader: (1)

Probably not messed up, but I'm thinking you have air trapped in it.