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Old 11-19-2002, 07:25 PM   #1
Sean
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Default New clutch acting weird: engagement point randomly changes on clutch pedal...

I just had Exeter Subaru install a ClutchNet six puck sprung copper rally clutch in the PGT car (MY96 Impreza L with cable clutch) along with a new stock flywheel, throwout bearing and pressure plate. After daily driving it for about a month the clutch started acting strangely.

When engaging the clutch pedal at low speeds (getting rolling from a stop or bumper to bumper traffic) sometimes the clutch engages when the pedal is an inch off the floor, sometimes two inches off the floor and sometimes two and a half inches off the floor. If I come to a stop on an incline and the car rolls backwards with the clutch disengaged in first gear, engaging the clutch "catches" a little bit when the pedal is an inch off the floor, the car lurches, but the clutch doesn't fully engage until the pedal is two and a half inches off the floor.

Does this sound like the throwout bearing binding up on the pressure plate and I'll have to take the vehicle in for service or might there something I can do at the clutch fork to take care of the problem? I've swapped suspension and most everything else but I don't have the facilities to drop the transmission myself to inspect the clutch and pressure plate internally (yet ).

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Old 11-19-2002, 07:28 PM   #2
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Hi!

I'd like to preface this by reminding Sean that I have NO CLUE what I'm talking about...

Is it possible the clutch cable was not well stowed? Maybe it's catching on something randomly and getting pulled out of whack?

I don't even know if your clutch uses a cable or hydraulics or what, just throwing out an idea. I've seen a similar situation with throttle cables once.
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Old 11-19-2002, 07:34 PM   #3
Sean
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Quite possibly...that's what I was thinking but haven't had a chance to have an assistant go out and push the clutch pedal for me while I watch the clutch fork. Assuming the cable moves freely and doesn't bind I was wondering if there are any adjustments I can do on the fork to alleviate this. For example, will tightening or loosening the cable at the fork to change the engagement point help?

Edit: Yes, I'm a stupid driver, not a mechanic.

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Old 11-19-2002, 10:32 PM   #4
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Default Re: New clutch acting weird: engagement point randomly changes on clutch pedal...

Quote:
I just had Exeter Subaru install a ClutchNet six puck sprung copper rally clutch ... After daily driving it for about a month the clutch started acting strangely.
Sounds like you just answered your own question. Didn't anyone tell you that copper clutches aren't designed with user-friendliness as a primary design goal? Otherwise, they'd install them as standard equipment in performance cars, no?
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Old 11-19-2002, 10:43 PM   #5
Sean
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Default Re: Re: New clutch acting weird: engagement point randomly changes on clutch pedal...

Quote:
Originally posted by wac
Didn't anyone tell you that copper clutches aren't designed with user-friendliness as a primary design goal?
Ha. Well, I understand and fully expected the rough engagement and studdering. I did not, however, expect the engagement point to randomly change depending on the mood of the car. From the feel of the clutch pedal it feels as if the clutch is getting caught on something or the fingers aren't evenly pushing against the clutch disc.

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Old 11-20-2002, 09:28 AM   #6
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I just put a similar clutchnet clutch & Primitive flywheel in my 1997 Impreza (cable style). There is an adjustment at the fork under the hood, however I maxed mine out. It engages about 1" from the floor however I've noticed that is snaps in quickly to about 85-90% engaged, then takes about another .75" to fully engage. I'm worried that my clutch cable (car has 120k miles on it) is stretched so that once wear occurs, I won't be able to fully disengage it... To aleviate this I'm planning to invest in a new one. Also there may be an adjustment at the pedal, however I haven't taken the time to look yet.

When my car has warmed up a lot, the clutch engagement point seems to move up the pedal some, but not more than .5-.75 inch.

Good luck with your problems... hope they get sorted for you.

I'll let you know if I find an adjustment on the pedal. I'll be putting my new pedals on this Friday and will look.. may take a gander tonight as well.

Thanks - Jon
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Old 11-20-2002, 02:26 PM   #7
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Yes there is a clutch pedal adjustment point. It is located above the gas pedal where the cable penetrates the firewall.
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Old 11-20-2002, 04:32 PM   #8
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HA! my stock clutch has acted like this as long as I remember! no two friction points are the same! makes for interesting driving


maybe it has something to do with how the clutch heats up? or when the engine/trany is warm/cold it changes the friction point? copper expands......

(I dunno! )
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Old 11-20-2002, 08:31 PM   #9
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Quote:
Yes there is a clutch pedal adjustment point. It is located above the gas pedal where the cable penetrates the firewall.
Does not apply to Sean's cable clutch.
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Old 11-21-2002, 10:49 AM   #10
Sean
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OK, I adjusted the bump stop just above the clutch pedal and tightened down the cable on the clutch fork. This got rid of some slack and play but didn't solve the weird engagement problem.

OK, wac (and anyone else with a cable clutch), if you grab the clutch fork with your fingers is it mounted pretty solid or can you wiggle it around about half an inch from side to side? Mine wiggles (yes, that's a technical term ) quite a bit. Perhaps the clutch fork is worn.

Next question, all the hydraulic Imprezas I've driven have an engagement point about an inch off the floor...is that possible to do with a cable clutch? Brian (North Ursalia) didn't seem to think so when we were poking at the car last night, but whenever I got my old cable clutch OBS back from tranny service the clutch engagement point was about an inch off the floor then, over the course of a few months, started to get higher and higher until it topped out at about 3 inches off the floor.

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Old 11-21-2002, 01:51 PM   #11
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You do still have your return spring on the clutch fork right?

You may want to consider a new clutch cable.... My OBS was an inch or more off the floor until I put in my clutchnet clutch and flywheel. Did you heavily grease the input shaft? What condition was your input shaft in when you installed the clutch... Oh wait you had it installed didn't you.

Jon
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Old 11-21-2002, 04:21 PM   #12
Sean
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Yes, the return spring is still there and greased heavily. The bumpstop adjustment is maxed out in an attempt to get the clutch at about the same level as the brake. Regarding the condition of the input shaft, no idea...everything was smooth and silky before the ClutchNet clutch went in.

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Old 11-21-2002, 06:01 PM   #13
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my bag,...cable...adjustable at the fork. duh.

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

quote:
--------------------------------------------------------------------------------
Yes there is a clutch pedal adjustment point. It is located above the gas pedal where the cable penetrates the firewall.
--------------------------------------------------------------------------------

Does not apply to Sean's cable clutch.
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