NEED CLUTCH HELP NOW! IT WORKS!!!!

[BLUCRUZ]

Just put in new motor & cluch/flywheel. Engine runs great but I can't put the rig in gear cause the clutch wont disengage far enough. I bled the out of it and still only feel preasure about 1/2 way down on the pedal. The Slave cyinder is only moving about 3/4 of an inch. Should't it be more like 1 or 1-1/4"? I need to move this thing tonight!-Help

It's a 85 4runner and the clutch is a luk from Marlin

[brainlessfool]

sounds like you mite have a bad master

[BLUCRUZ]

It was fine before tear down. I only put a new clutch in it because I was going to have the engine out. I never diconnected the slave and no fluid loss either. I'm pissed, it's like the clutch is shorter or something even though I know it's not

[Prismo]

Did you adjust the pedal free play? You may have to adjust the rod inside the master cylinder if you have freeplay. I have also seen slave cylinders have an adjustable rod.

[BLUCRUZ]

Did you adjust the pedal free play? You may have to adjust the rod inside the master cylinder if you have freeplay. I have also seen slave cylinders have an adjustable rod.

Yea, it's almost all the way out now. Is the pivot rod in the bell housing adjustable? I pulled the rubber around the fork rod and it looks like the throwout bearing is about an 1/2 inch from the presure plate?

[Prismo]

As I recall it is not adjustable. Seem to remember it is just a threaded post, but I could be wrong. Sounds screwy somehow with the problems you are having.

[BLUCRUZ]

As I recall it is not adjustable. Seem to remember it is just a threaded post, but I could be wrong. Sounds screwy somehow with the problems you are having.

Tell me about it, I've never had this much trouble with a clutch, I've tried everyting I know-I am going to put in a new slave since they're cheap and see if that helps-I'm just not getting enough swing on the fork rod?

[Prismo]

I just went & measured the amount of movement in my slave when depressing the pedal. It is very close to 3/4" on mine also. Was the throwout bearing the same as the old one? It almost sounds like the diaphram springs don't stick out as much as the old one.

[BLUCRUZ]

I just went & measured the amount of movement in my slave when depressing the pedal. It is very close to 3/4" on mine also. Was the throwout bearing the same as the old one? It almost sounds like the diaphram springs don't stick out as much as the old one.

Not exact but it was the same thickness-by the way the old clutch was a luk as well just not the heavy duty one. It's close, I mean if it will move another 1/8 inch it will disengage.

[Prismo]

I am out of ideas. it will probably be something simple that we didn't think of.

[WHITE_TRASH]

I did a clutch job in highschool on a datsun car and had the exact same problem.  It was weird I replaced the whole assembly with another one, same brand and everything andit did the same thing as yours.  I never opened the hydrolic system or anything but it just didnt have enough travel after the clutch job.  I ended up using a long 3/8th's bolt with the head and threads cut off and made myself a new slave to fork rod.  Hope this helps I know these things can be mind boggling.

[BigMike]

Well was your flywheel surfaced correctly? If it was surfaced more than about 28 thou then the disk would never disengage

Slave cyinder is only moving about 3/4 of an inch

That sounds right. It doesnt take much for the piviot. If someone else could check their's that would be helpful

[Prismo]

I checked mine, it was right at 3/4.

[BLUCRUZ]

Well was your flywheel surfaced correctly? If it was surfaced more than about 28 thou then the disk would never disengage

Slave cyinder is only moving about 3/4 of an inch

That sounds right. It doesnt take much for the piviot. If someone else could check their's that would be helpful

Brand new flywheel, I'm going to try making a new rod for the slave. Mike I bought this from you guys about 2 weeks ago and it's been in the rig since then, just now got around to finishing up the new engine- Have you guy's ever had this happen before?

[BLUCRUZ]

It's soo close! I actually drove it out of the driveway a few minutes ago, but it's still not right, I'm going to try a bolt/rod that is 1/16 of an inch longer and see what happens.

[Prismo]

Did you get it fixed?

[BLUCRUZ]

My clutch pedal is about a inch higher than my brake pedal inside and sucks cause I'm 6'3". I forgot about about the stopper inside that allowed my pedal to move back towards the seat more I couldnt see it cause of the heater duct.  I thought I had adjusted it out as far as I could before but i got another 4 turns on the M/C rod before it fell out. It's driveable now. I'm still not happy with it but i'll give it a couple days and tinker with it more.

[79coyotefrg]

i have marlins 1200 clutch and a .050 turned flywheel,with of course a .050 shim behind the flywheel  i have the adjustable slave rod and had to extend it  to the very end befor i could drive it,  it looked to me that the disc was  thicker on marlins , than on the stock clutch,  but i was able to drive it,  its been driven hard for a year now and i h avent had any problems other than tires spinning  on pavement

[BigMike]

it looked to me that the disc was  thicker on marlins , than on the stock clutch

I believe this is true. I've never measured the two, but our clutch disks look incrediable beefy compared to a stock clutch disk so I wouldn't be suprised. But, the disk and pressure plate are a matched set. They are built within specs for each other. In fact, the Toy manual says to surface the flywheel 0.020" but surfaces his flywheels to about 0.026" or so and his clutches still work. The friction point is wwaayy at the bottom which means you will get a full life outta the clutch disk. So if we can get them to work at 0.026" then it of course will work at 0.020" which is stock specs.

Regards,
BigMike

[BLUCRUZ]

ADJUSTED A BIT MORE AND HOLY SNAPPING TURTLE BATMAN!  WORKING GOOD! THANKS ALL

[WHITE_TRASH]

Glad to hear it!  I hate those kinda problems.