clutch problems?!

[futurehachi]

Hi guys, I recently just got my car all back together after rebuilding my engine.
My clutch was fine when I took it all apart. I made sure the disc was facing the right way, and properly aligned.
On the first test drive, I drove about 9 blocks to the gas station. It had no issues, as I left the gas station parking lot I started getting a pop noise when my pedal got close to the floor and my TOB started squealing. I am not worried about the tob noise since I know what it is.

I am trying to figure out what the pop is. It was still driving pretty well other than my clutch pops when I get my clutch near the floor.

Most recent issue is that my slave cylinder blew out. Could the noise/strange pedal feel have been from the slave cylinder being on its way out?

Any ideas/ suggestions/ help will be appreciated

[futurehachi]

New issue.
I installed a new slave cylinder. Car moved with no clutch issues. I backed it up in the driveway and let it warm up. I went to leave after letting it warm up. It refused to go into gear. Pressed the clutch a couple times and the pedal went to the floor. It pushed the piston out of the cylinder and the pushrod was still against the clutch fork.

After that, my TOB started squealing at idle.

Is it possible that I mis-assembled it? Like could I have put the tob in backward? Or could the clutch fork just be in wrong?

Somebody please help??!

[futurehachi]

Examined it through the clutch fork hole. Broken spring on my pressure plate

[jondee86]

Pressed the clutch a couple times and the pedal went to the floor. It
pushed the piston out of the cylinder and the pushrod was still against
the clutch fork.... Or could the clutch fork just be in wrong?

The clutch fork is held in place by three spring clips with a tiny bit of
assistance from the rubber boot. After assembling the clutch fork to the
gearbox, do not use it as a handle. If you use the end of the fork for
lifting and/or manouvering the gearbox into position under the car, it
is easy to dislodge the fork from its correct mounting position.

Sounds like this is what happened to you ?

Cheers... jondee86

[futurehachi]

Pressed the clutch a couple times and the pedal went to the floor. It
pushed the piston out of the cylinder and the pushrod was still against
the clutch fork.... Or could the clutch fork just be in wrong?

The clutch fork is held in place by three spring clips with a tiny bit of
assistance from the rubber boot. After assembling the clutch fork to the
gearbox, do not use it as a handle. If you use the end of the fork for
lifting and/or manouvering the gearbox into position under the car, it
is easy to dislodge the fork from its correct mounting position.

Sounds like this is what happened to you ?

Cheers... jondee86

I believe this may have been an issue also, but I did also break a spring on my pressure plate.

If one of them broke, causing my issues to worsen can I buy replacements?

[jondee86]

It's time to do the job properly. Pull the gearbox and get yourself a
new clutch kit (pressure plate, disc and throwout bearing). Check the
pilot bearing and replace if in doubt. Press the new throwout bearing
onto the sleeve, grease the parts that need to be greased and clean
the parts that need to be cleaned.

Assemble and torque the clutch to the flywheel using a clutch alignment
tool. Assemble the fork to the gearbox making sure all the clips are in
place... then fit the box making sure you don't apply any force to the
outside end of the fork.

Clean and re-assemble the clutch slave cylinder, install to the box and
bleed using fresh fluid. Make sure the pushrod moves the fork about
8mm (?) and retracts. Adjust the clutch pedal if necessary, to ensure
there are few mm of freeplay before the pedal starts to push the piston
rod into the master cylinder. Test drive

Cheers... jondee86

[redbeltpanda]

good write up to refresh our mechanic skills

[futurehachi]

It's time to do the job properly. Pull the gearbox and get yourself a
new clutch kit (pressure plate, disc and throwout bearing). Check the
pilot bearing and replace if in doubt. Press the new throwout bearing
onto the sleeve, grease the parts that need to be greased and clean
the parts that need to be cleaned.

Assemble and torque the clutch to the flywheel using a clutch alignment
tool. Assemble the fork to the gearbox making sure all the clips are in
place... then fit the box making sure you don't apply any force to the
outside end of the fork.

Clean and re-assemble the clutch slave cylinder, install to the box and
bleed using fresh fluid. Make sure the pushrod moves the fork about
8mm (?) and retracts. Adjust the clutch pedal if necessary, to ensure
there are few mm of freeplay before the pedal starts to push the piston
rod into the master cylinder. Test drive

Cheers... jondee86

Thanks for the write up. I am ordering an exedy kit later on today. I bought a new slave cylinder already, because I had been getting fluid behind the boot for a while. My pedal already has the bit of free play. I just need to wait for the new clutch