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Old 11-11-2014, 10:17 PM   #1
bluto555
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Member#: 228776
Join Date: Nov 2009
Default Another.. My new clutch wont disengage! thread.

Soo,

My new clutch wont disengage!

2004 wrx, new exedy ksb03 clutch kit, resurfaced flywheel. New/used, known good shortblock.

Start car, cant put it in gear. shifts fine with car off.
Start car in gear, creeps forward but it will idle and there are no crazy noises.

drove car for about 2 miles with no oddness just no shifting. no change in situation.

Remove tmic bleed slave using various recommendations found searching and same result.

attempt to manually pry out tob fork, it moves maybe a little, still cant shift. tob fork is less than a 1/4" from edge of the opening when maxxed.

Engine back out... Removed clutch after visual inspection, also removed flywheel.

everything looks fine. disc and pp part numbers check out ok. Pilot bearing is smooth and free, shows no sign of abuse.

At this point im wondering wtf..

I had to draw the engine and trans together a little more than usual. It seemed because of poor dowl alignment/cruddy holes. this was definitly the case.

Also, I torqued the pp to 20 ft/lbs. i have since read the factory torque is 13ft/lbs. I have also read one post on nasioc say that over torqued pp bolts can prevent full disengage. this doesnt seem likely to be my problem but...?

disc thickness is .320"
disc sitting on pp sits about .190" proud of the pp mating surface(same as the old pp.)

soo... any ideas?
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Old 11-11-2014, 11:01 PM   #2
ride5000
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Member#: 32792
Join Date: Feb 2003
Chapter/Region: NESIC
Location: lincoln, ri
Vehicle:
2003 GGA MBP
12.9 / 105+

Default

did you snap the TOB into the PP after assembly?
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Old 11-11-2014, 11:18 PM   #3
bluto555
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Member#: 228776
Join Date: Nov 2009
Default

so looking at what i believe is the fsm for 2004, the thickness listed for the 2.0 turbo clutch disc is .138"... errm? I guess they are offering up a measurement of the friction material per side only. i didnt get this measurement.

Reading further, the sti disc has a listing for both flywheel side and clutch cover side @ .126" and .128" respectively. this makes a little more sense. but im still somewhat surprised that there isnt a total thickness listed.
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Old 11-15-2014, 11:18 PM   #4
bluto555
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Member#: 228776
Join Date: Nov 2009
Default

https://www.youtube.com/watch?v=-NAxb_uU1Ys

I watched this exedy usa tech video to see if I had missed something or if there was some subaru specific issue to watch out for.

buggered up input shaft splines were brought up as a possible clutch drag issue and it was recommended to check the disc on the input shaft.

My car had sat for a bit and had some rust on the input shaft. I wire brushed the rust and lubed everything up but never tried the disc on the shaft.

With everything taken back apart i put the disc on the shaft and it was pretty clear that it was still bad enough to cause an issue.

ran a pick through the spline grooves, tried the disc on the shaft again with much better results.

put everything back together and problem solved, happy ending.
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