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Old 10-01-2013, 07:33 AM   #1
Von_holbrook
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WRB+Gunmetal Volk's

Default Issue with clutch fork/cylinder

I posted this in another section and was unable to get much help. I bought my 03 without a motor, got a motor new clutch etc. The clutch fork and the pin that goes through it and the trans were removed by the previous owner. Upon installing the new clutch and flywheel i noticed that I was unable to move the fork up to align the holes on it to the trans where the pin goes in. I didnt think nothing of it, so I installed the throw out bearing on the fork and realized that my inability to do so may be a problem. Someone suggested unbolting the master cyl from the trans then inserting the pin through the fork and closing up the trans/engine. Therefore I did so and the TOB clicked on to the pressure plate as it should and the pin was easily inserted through the trans and fork. Now my problem, the cylinder wont bolt back up to the trans. when I push down on it to align the holes the pin coming from the clutch fork into the master cylinder prevents me from doing so and stops me about a half inch short. Also the pin came out from the cylinder once and was almost stabbed through the boot. I have tried fully depressing the cylinder and i'm still unable to bolt it back up to the trans. I have tried to explain this to the best on my ability, and any help will be greatly appreciated!
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Old 10-01-2013, 10:34 PM   #2
Von_holbrook
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Default

Bump...
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Old 10-06-2013, 06:53 PM   #3
Von_holbrook
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Can someone help me out?
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Old 10-12-2013, 01:09 AM   #4
Von_holbrook
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WRB+Gunmetal Volk's

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Bump.....
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Old 10-12-2013, 06:53 AM   #5
Von_holbrook
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I meant slave cylinder by the way, and bump...
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Old 10-12-2013, 10:48 PM   #6
nmlittlebigman
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Default

So did the previous owner part it out? If so he may have had a 6 speed transmission which he sold, and then you got the car with the original the 5 speed trans and a 6 speed clutch fork. See: http://forums.nasioc.com/forums/showthread.php?t=912554
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Old 10-13-2013, 02:02 AM   #7
Von_holbrook
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I like the way you think. I called him up and asked him but he said he never swapped the trans. But it's like the clutch fork is either too long or the slave cylinder isn't the right one. He couldn't talk long so I wasn't able to ask if he had swapped either of the two before selling.
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Old 10-14-2013, 07:19 PM   #8
donkey_cart
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.....

Last edited by donkey_cart; 12-13-2013 at 06:14 PM.
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Old 10-15-2013, 02:26 AM   #9
Von_holbrook
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Before I give this a try, what kind of issues would I run into if the clutch I got was the wrong one? For example if I had a push style pressure plate instead of pull? Would this cause the same issue?
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Old 10-15-2013, 02:29 AM   #10
Von_holbrook
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Old 10-15-2013, 02:31 AM   #11
Von_holbrook
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I assume this is a pull TOB & PP? This picture was taken before the motor went in.

Last edited by Von_holbrook; 10-15-2013 at 04:38 AM.
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Old 10-15-2013, 03:21 PM   #12
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.....

Last edited by donkey_cart; 12-13-2013 at 06:16 PM.
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Old 10-15-2013, 04:21 PM   #13
DaveSB
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Quote:
Originally Posted by donkey_cart View Post
Correct, that looks like a pull type (02-05 WRX). Make sure both clutch fork ends are inside the TOB tabs and not outside of them. That will also cause the issues you are having.

What kind of clutch is this? That pressure plate looks massive.
It's a Competition Clutch. It is from a 5spd 2.0l WRX and I imagine it's the camera angle that makes it look larger than average.
I could be wrong, but my understanding is that the bearing needed to be mounted on the clutch fork and the trans being installed is what clicked the bearing into the pressure plate. Maybe someone can chime in on that. If so, just take a flat bladed screwdriver and slip it between the locking ring on the pressure plate and the bearing. Turn the screwdriver sideways and pull out on the bearing, it should come right out.
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Old 10-15-2013, 04:59 PM   #14
Von_holbrook
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Default

I didn't install the TOB like this. I put it on the forks and shaft first then clicked it into the plate after the motor & trans were together. But I had to unbolt the slave cyl from the trans to get everything lined up. The pin inside the slave cyl seemed to stop the fork from lining up to the holes for the shaft that goes through the fork.
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Old 10-15-2013, 07:19 PM   #15
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.....

Last edited by donkey_cart; 12-13-2013 at 06:16 PM.
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Old 10-15-2013, 08:11 PM   #16
Von_holbrook
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Default





The first is with the fork fully depressed into the cylinder with me pushing down on top of it, the rod inside of the cylinder stops it from going down. She second is everything just there. Clutch is depressed in both and the fork is all the way in the TOB.
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Old 10-15-2013, 09:36 PM   #17
nmlittlebigman
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Are you sure that the slave cylinder pin goes thru the fork??? These photos show that that hole is for a spring and the pin contacts the fork closer to the trans

http://forums.nasioc.com/forums/show....php?t=2510958

http://ww2.justanswer.com/uploads/Su..._image_000.jpg
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Old 10-15-2013, 09:48 PM   #18
Von_holbrook
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Default

I'm not sure at all, this is the way it was put together when I got the car. There is a slight indention on the back of the fork so this is something I will have to look in to tomorrow. Why would someone put the pin into the spring hole anyway??
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Old 10-16-2013, 04:58 PM   #19
Von_holbrook
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This fixed my problem! Thanks guys, but the motor I just put in ended up being bad. So 5 months of work down the drain..
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