Weird clutch problem - HELP please?

[gregmc]

(Posted this on the 3Si board, but getting little response. Hope the experts here can help.)

I put a new (well, used JDM) motor in my car in January. As a part of the swap, I put in a new clutch, throwout bearing, and slave cylinder, and resurfaced the flywheel, . I had to make a longer push rod so that everything worked since I didn't put in spacers after the resurface. Now I'm having a weird problem.

When I start the car in the morning, the clutch is easy and I don't have any problem getting into gear, even reverse. I have a 55-mile (mostly highway) drive to work. By the time I get into town, the clutch pedal is almost impossible to push to the floor and it's difficult to put into 1st. Reverse is impossible when the motor is running.

I did check the fluid and it was a bit low. Filled it. No change.

I did some searching here and didn't find anything. I suspect either the throwout bearing or slave cyl. One easy, one hard.

ANY help or expertise is greatly appreciated.

Thanks in advance!

-- G

--------- Postscript

A 3si brother suspected that "one of the seals has deteriorated to the point where it's generating excess resistance" and admittedly rare possibility that "the flexible clutch hose that attaches to the slave could be collapsed internally". What I don't understand is why it might come and go with use or heat. I'm willing to do what it takes to fix this, but would like to have more info. I hope someone can expound, concur, or contradict. What seals would be most suspect? Help in narrowing where to look would be most helpful. Thanks -- G

[detpac]

I dont think its the slave cylinder. I had a slave problem but iw as just the opposite of your problem..Good pedal and gears in am but after 4 minute drive, the pedal went straight to the floor and I had no pressure unless I pumped it a few times.

I would look at your throwout bearing.

Any others on the board may provide better help.

[gregmc]

One thought I had is that when I put the engine in, I didn't get the trowout bearing in correctly. Might also help explain the need for the longer pushrod. Is it possible to put these in wrong and have it still work? I'm no clutch expert, so could it be in backwards or have slipped off the fork?

If not, any other theories?

Thanks! -- G

[gregmc]

Any thoughts or suggestions are welcomed.

Thanks -- G

[Racer 007]

I am no expert, but I am going to concur with Detpac on this. I think it may well be your throwout bearing. When I had my first clutch replaced, it worked fine initially for about 5 or 6 miles first thing in the morning although I would have to jiggle it into 1st from neutral. I have massive stop and go traffic on the way to work. My problem wasn't as bad as yours but it would become extremely difficult to push it into 1st gear even when my pedal was all the way to the floor. It would require me to jiggle the shifter into position sometimes grinding it in. By the time I made it out of the traffic and started to utilize 2nd and 3rd gears, I would have the same problem, jiggle and grind. In the afternoon when I would leave work, it was almost impossible to back out of my parking spot. 9 times out of 10 I would have to grind it into reverse from neutral. When I took it into Mitsu, I had learned that the incorrect throwout bearing was being used. I replaced that and the clutch and have had no problems since.

Another thing I noticed was that you resurfaced your flywheel. I have heard from Mitsu and many other sources, including Matt @ DR, that you should never resurface your stock flywheel. Not sure if this is part of your problem. If your throwout bearing has been installed incorrectly and or is the incorrect one, couple that with a resurfaced flywheel, may explain your problem.

I would at least have your throwout bearing checked out. Hope this helps.

[detpac]

I agree. It is possible to put in a throwout bearing incorrectly and have it work the way you described. Have it checked out.

[gregmc]

Thanks for your suggestions and experiences. Here's a link to the sister thread on 3Si:
http://www.3si.org/portal/forums/showthread.php?s=&threadid=112131

While I have a couple things to look at before pulling the tranny, ultimately sounds like I'm going to have bite the bullet and dig in. Ugh ...

I appreciate your help!

Cheers -- G