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Old 12-23-2014, 12:02 PM   #1
Deano1022
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Default Trans problem, its not the most wonderful time of the year

2007 WRX 5spd.(Catless TBE, SPT intake, opensource tune, nothing crazy)

Replaced clutch around a year ago(ACT stage 2, light flywheel(me and a buddy with a lift)). No issues with it in that time.

Over the weekend the clutch is not disengaging fully(cannot get into gear while running, can start in gear, let clutch out a fraction of an inch and you're off and running). Played around with pedal adjustment slightly, no help. Had my wife push in clutch, watch the slave move and push the fork. Removed slave, fork is loose and appears lopsided(bent). Pulled the boot and peered in. Nothing to weird looking, just that the fork is really loose. The forks clips are in place to some degree.

Got a rental((Prius ugh)my wife and I share one car). I have no way to rip this thing apart in the next week. Called a few shops, can't even see me until Monday.

Any band aids you guys can thing of? Or diagnosing without dropping tranny.

I am wondering if I can stick a block(metal, wood) on the fork to take up the slack to see if I can get the clutch to fully disengage. At least tell me if that's where the problem is or if its something worse(TOB or pressure plate).

Going to take a picture/video when I get home.

Thanks
Dean
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Old 12-23-2014, 01:24 PM   #2
Snowphun
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I dealt with a lot of similar issues when I did my six speed swap. If the clutch doesn't disengage it suggests to me you've got a hydraulics issue, either the slave is bad or you've got air or a leak in the system? The clutch rod adjustment under the dash has a lot of range, you should be able to make a difference with that.

Not suggesting it's as bad as this, but it came to mind since you said the fork is loose. With the fork rod in place it really shouldn't move at all. http://forums.nasioc.com/forums/showthread.php?t=778422
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Old 12-23-2014, 03:42 PM   #3
Deano1022
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Thanks Snow

Hopefully I can get a good shot of it and you can see what I mean about it having slack.

Unfortunately I tried to bleed the slave the "old fashioned way"(pumping and releasing, so now there is zero pressure. Should have read up on it first...

I am grabbing a mityvac on my way home to bleed it out tonight.
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Old 12-23-2014, 03:58 PM   #4
Snowphun
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Bleeding that clutch sucks, I couldn't get it done well so I took the whole system out of the car in one piece and bench bled it. Was pretty easy to remove, just a bit of wiggling and got the job done right.

Post your issue in the trans and drivetrain section, many more eyes in there that will have better advice.
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Old 12-23-2014, 04:27 PM   #5
lpxltt
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Hey, just noticed you were in my home town. I have a pneumatic bleeder if you want to borrow it. Works pretty well.

My guess though is that the fork is bad. They can wear and crack causing the symptoms that you describe. Its a $25 part at the dealership, make sure you grab a spring too. If you need a hand, let me know. I'll be around off and on around this weekend.
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Old 12-23-2014, 06:15 PM   #6
Snowphun
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I'm in Middleboro too, must be a hot spot for Subies now. If it is the fork you're splitting the trans and engine, so make sure you're confident before you go that route.
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Old 12-23-2014, 06:33 PM   #7
lpxltt
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So apparently we need to have a Middleboro meet some time! After Dean gets his issue fixed maybe we can take a cruise down to Plymouth or something.

Dean, offer still stands. I have a couple hours free tonight so if you need a hand let me know.
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Old 12-23-2014, 09:50 PM   #8
Deano1022
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Wow you guys are awesome.

We I went to autozone after work to grab a mityvac. Of course they were sold out, I bought one of those "one man bleeders" that didn't help. Pumped and bleed for a couple of hours(did get air and fluid, nasty milky fluid), pedal still sitting on the floor. Gonna have to pull the system, you're right it doesn't seem bad, I had the slave and master off independently at some point today. I'm sure I will grenade a hardline or something in the process LoL.

This is the play in the fork. The slave will actually go back another another 1/4 inch or so.

Picture of the fork, looks crooked to me, I may have just convinced myself of that at this point. [IMG][/IMG]

If it does end up being the fork, I did a clutch in this around a year ago, so you can imagine I will be psyched to pull it back apart. Wouldn't being doing it in my driveway that's for sure.

lpxitt I'm going to send you a PM, I'm done for tonight but maybe after the holiday

Thanks again guys. First vid and pic post so hopefully I did it right.
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Old 12-23-2014, 11:14 PM   #9
Snowphun
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I have my IC off at the moment and just tried to move my fork around by hand: no movement whatsoever with the car in gear. In neutral it has just a bit of play in every direction.

The amount you're able to push the slave in makes it look like it has air in it, mine is stiff and hard to move by hand. But the side to side is alarming. After you bleed the system you may need to pump the peddle a few dozen times to get it back to 100%.
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Old 12-24-2014, 01:36 AM   #10
lpxltt
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There is a little play side to side on mine as well but nothing back and forth.

The milky fluid generally means water mixed with the fluid somehow. You may have a leak somewhere. How does the reservoir look?

Edit: Just noticed the PM. Replied.
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Old 12-24-2014, 08:20 AM   #11
impreziveWRX521
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i had an issue similar to this a while ago. the clutch fork was crooked like in your pic, which let air into the system through the slave cylinder. the cause of the issue was the throw out bearing, one of the ears broke off.
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Old 12-24-2014, 11:15 PM   #12
aerosaaber
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my throwout bearing recently exploded after making a hell of a racket and making use of the clutch very difficult. It also chewed the hell out of the transmission case where it slides (so the shop threw a transquil sleeve thing in). Was it making any noise before this?
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Old 12-25-2014, 10:40 AM   #13
Deano1022
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No, no noise to speak of. I drove it on Saturday with no issues, and the wife took it out Sunday and told me later she had some trouble shifting but nothing really "wrong" with it. Then that night no pressure in the pedal.

When I did the clutch, I looked into the snout repair kit but it all looked fine when I pulled it apart.

I can see one side of the TOB through the cutout where the fork is positioned(looks good from that angle), but not the other side.

Hopefully I can get it bled(I let so much air in trying to bleed it....) and see how it functions. I don't see any leaks but maybe once it's fully pressurized I'll see something. That's almost the best case scenario at this point, so I don't have to pull the trans.

Thanks for all your advise and help guys. It means a lot to me
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Old 12-25-2014, 10:47 AM   #14
Annihilator817
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If you were bleeding alone, and pumping the clutch, you probably sucked air into the line, even with the one man bleeder.

I would just try a gravity bleed so you know you got the air out.

Or get your wife to pump the pedal while you bleed.
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Old 12-25-2014, 05:51 PM   #15
Snowphun
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I tried all sorts of solutions before finally pulling the whole system out and bench bleeding. Apart from being a bit of a handful to put back in (make note of your removal procedure) it was easy and provided great results first try.

I'll be in Middleboro this weekend if you want a hand or a second set of eyes.
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Old 12-26-2014, 06:11 PM   #16
Deano1022
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Well boys, got it bled, finally. Benched bled it twice(I think I screwed up the first time), installed, goodish pedal(returned back to disengaged position anyway) couple pumps and bled on the car(thank you wife) and I could get a good view of the other side of the clutch fork. I can see it's cracked around the pivot point. UGG. Knew this was an issue for the RS guys but didn't really see it being a problem on these. Oh well

Time to pull the trans...
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Old 12-26-2014, 06:56 PM   #17
lpxltt
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Damn, that sucks. The fork is cheap enough that I replaced it when I did my throwout bearing in my car and the clutch in my wife's car. When you do it, make sure you grab the little spring as well. Probably a good idea to replace both bearings too if they are original.
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