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Old 10-17-2006, 06:02 PM   #1
ride918
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Angry clutch not disengaging!

well I just replaced the motor in my '03 wrx wagon and everything is running great but my clutch is not disengaging, it disengages enough so that the car will run in gear with the clutch in but I cant get into gear unless the car is off and when I start the car while in gear I can feel it jump forward a little. The fork is on the TOB and I tried bleeding the clutch. The suby dealer thinks I put the disk on backwards but I am pretty sure I didn't do that. Btw I put in a spec stg 1 clutch and resufaced the flywheel. I tried searchin the forums but all the threads I found had no answers. any tips or advice is greatly appreciated. thanks

cory
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Old 10-17-2006, 06:16 PM   #2
kcook
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who installed it? u?
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Old 10-17-2006, 06:18 PM   #3
dibblejr
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Suby dealer is probably correct. Did you put a new TOB and is the TOB on the fork correctly?
Also check your linkage to ensure you got them on correctly before you tear into the tranny again.

Jay-R
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Old 10-17-2006, 06:29 PM   #4
ride918
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my friend and I did the install. the clutch came with a new TOB and it is on the fork, each side of the fork goes in the tabs on the TOB. I am pretty sure the linkage is exactly the way it was when I took it off(can it really go any other way?). I really hope the disk isn't on backwards. It even had a sticker that said "fw". anyone know of any pics of the linkage? thanks for the fast replies.

cory
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Old 10-17-2006, 07:28 PM   #5
dibblejr
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Stranger things have happened than putting the linkage on wrong. One more thing, have you looked at adjusting the clutch pedal. ( just another thought) I hate to see you have to tear into the tranny. Big PITA to have to redo.

Jay-R

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Originally Posted by ride918 View Post
my friend and I did the install. the clutch came with a new TOB and it is on the fork, each side of the fork goes in the tabs on the TOB. I am pretty sure the linkage is exactly the way it was when I took it off(can it really go any other way?). I really hope the disk isn't on backwards. It even had a sticker that said "fw". anyone know of any pics of the linkage? thanks for the fast replies.

cory
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Old 10-17-2006, 08:13 PM   #6
ride918
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I have searched the thought of adjusting the pedal but most I mostly found that this will only adjust the free play and that it shouldn't be adjusted very much, in fear of wearing out the mc. thanks

cory
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Old 07-20-2010, 02:35 PM   #7
sti05subie
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i am having the same problem with my sti. i had the flywheel resufaced and got a new exedy cerametallic stage 2 clutch kit. it wont disengage all the way. please help i dont want to take the car back apart if i dont have to. Thanks ,Travis
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Old 07-20-2010, 02:41 PM   #8
dibblejr
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Try bleeding the cylinder. If that doesnt work probably a new slave cylinder is in order. I have had a couple of really tuff clutch installs with the same problems and both times it was the slave cylinder needed some serious bleeding and in 1 case the boot was shot so had to get a new slave cylinder.

I have changed many many suby clutches. Of course this only applies if the clutch and everything was installed correctly.
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Old 07-20-2010, 02:46 PM   #9
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When bleeding the clutch cylinder you will need a friend just like bleeding the brakes they will have to pump the clutch pedal as fast as possible and all the way to the floor. Sometimes it even has to be done by hand instead of foot. As you fill the resevoir you can see the little pushrod that makes contact with the clutch fork, normally as you described the pushrod is not contacting the clutch fork or is not pushing it hard enough.

Also ensure that the clutch fork is correctly installed. You can remove the spring and slave cylinder and the clutch fork should be slightly loose and can be wiggled around and up and down. If it is tight the clutch fork pin may not be seated correctly. A lot of people have problems trying to get the pin in on the reinstall due to the alignment.

GGood luck, hopefully bleeding will solve the problem.

Jay-R
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Old 07-20-2010, 02:49 PM   #10
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i have tryed that and i cant see how it could be installed wrong. it would only go in one way. thank you for the ideas. Is it ok to resuface an 05 sti flywheel. and does anyone know the specs for machining?
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Old 07-20-2010, 02:50 PM   #11
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FYI- I have bled the clutch slave cylinder by myself from under the hood but I have a lot of experience, it is a PITA but can be done. But safer and easier to have someone pumping the clutch pedal by hand or foot or combination. Normally in this situation the pedal will stick to the floor until pulled up and pumped by hand enough to get the pushrod working by foot.
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Old 07-20-2010, 02:52 PM   #12
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Yes you can resurface flywheels and if the business that resurfaced it is legit they cannot resurface a flywheel or break rotors that will not be within specs.

Try bleeding the clutch fluid 95% that is gonna be the problem.
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Old 07-20-2010, 02:55 PM   #13
sti05subie
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ok thank you i will go and try doin that again.
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Old 07-20-2010, 02:57 PM   #14
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One more thing- no matter what the flywheel surface is like it would have no impact on the clutch not engaging. (unless it is destroyed, obviously).

Did you install a new PP, TOB and Disk at the same time? It is always best to change it all at once so that everything mates up.
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Old 07-20-2010, 03:00 PM   #15
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Bleeding the slave cylinder is not something that will take 5 minutes. It may take quite a while to get all of the air out. I know the fluid line is very short but it should be done patiently. On occassion I have used a couple bottles of fluid just to ensure the old fluid is all purged and the clutch works correctly.

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ok thank you i will go and try doin that again.
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Old 07-20-2010, 03:03 PM   #16
sti05subie
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i replaced the clutch, pressure plate, pilot bearing, and tob. the clutch wont disengage completly.
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Old 07-20-2010, 03:05 PM   #17
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Disk in backwards. Who said that? the mechanic? Not possible. Flywheel is flat.

It could be the slave. As that is common. If you think it's got air in the system. Press the clutch top to bottom 100 times. Then re-bleed the system.
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Old 07-20-2010, 03:06 PM   #18
dibblejr
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Sounds like bleeding should correct it just take your time and remember it may not happen the first time.

Start the car with the e-brake on and have your friend help bleed. You can also try to push your car a foot or two forward or backward to turn the flywheel a tad and see if that helps.
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Old 07-20-2010, 03:14 PM   #19
sti05subie
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thanks ill keep tryning to bleed it. i talked to the dealership and they said that your not supposed to have an sti flywheel resurfaced. they said i would have to replace it. is this possible?
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Old 07-20-2010, 03:56 PM   #20
sti05subie
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still no luck.. iam gonna have to take it back apart.
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Old 07-20-2010, 04:05 PM   #21
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is the slave cylinder in the clutch fork hole/dimple correctly??
i had one that i installed and didnt notice that i didnt put it in hole/dimple correctly and if i remember correctly clutch didnt release all the way.
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Old 07-20-2010, 04:05 PM   #22
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Its gonna take you longer than you think. You need to keep trying, the last thing you want is to take it all apart.

Dealerships just want your $. A resurfacing has nothing to do with the clutch not engaging.

Ive been doing this for more than 20 years.
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Old 07-20-2010, 04:52 PM   #23
bswilmington
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Quote:
Originally Posted by dibblejr View Post
Its gonna take you longer than you think. You need to keep trying, the last thing you want is to take it all apart.

Dealerships just want your $. A resurfacing has nothing to do with the clutch not engaging.

Ive been doing this for more than 20 years.
i think you mean disengaging dont you? if you dont cut the tabs where pressure plate bolts down then i could see engagment problem as flywheel surface and pressure plate surface will be out of spec and not allowing pressure plate to put full force on disk and let it slip, but this isnt his problem

but if you over cut the tabs/towers whatever there technically called on flywheel then you could have clutch that doesnt want to fully disengage.

as dibblejr is stating i would try to find the problem cause if someone else has to find it then its gonna cost you. bleeding clutch is free plus while your there look for other problems that you may have caused. you can move the boot away and look down into the clutch area to see if anything is wrong also
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Old 07-20-2010, 04:53 PM   #24
sti05subie
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its in the dimple. and its not disengaging. thanks for the ideas
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Old 07-20-2010, 04:59 PM   #25
dibblejr
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If this happened last week I was in NY for a couple weeks and drove through PA and would have dropped by to get this fixed, for a lunch or dinner. Bad timing.

As I stated above almost 95% sure it is the slave cylinder and the bleeding.

Should not be any PP alignment issues since you needed an alignment tool to get everything back together.

Hope to hear you get it resolved, let us know.
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