I took the dog out to the beach for a run earlier today, its about a 15 mile trip out there and as i downshifted to swing into the carpark my ute crunched into second (never done that before) about the time i i found out that the clutch wasn't declutching....peddle on the floor and still driving as though i wasn't touching the peddle.

 

clutch cable isn't broken and the peddle feels weird almost like the clutch diaphragm spring has inverted

 

got to pull it apart tomorrow night after work....i'll just have to bomb around in my work truck until i can get it sorted

 

Probably a broken clutch fork.

well the clutch fork is ok....one of the spring clips that holds the throw out bearing to the clutch fork is broken but i can't see how that would stop the clutch from working...didn't get time to pull the pressure plate and clutch plate off the flywheel but a quick look doesn't show anything obvious from the outside....the saga will continue tomorrow night if i finish work early enough to get some work done on it

Had a '79 Dodge Omni, similar clutch set up with the clutch disc recessed in the flywheel..

 

Clutch disc shattered, loose bits wedged in with un-broken parts and wedged the clutch so it was always engaged.

 

That was a 1st for me.

yeah actually something like that is pretty high on my list of suspicions

If the peddle went to the floor, I'm willing to bet it's the fork. Even if it isn't visible from the top. I've had that happen before to on a '91 Legacy.

Have you tried gear meshing at the right RPMs? Starting cars in 1st gear is always a treat.

check ball pivot on fork for exess wear and buy new spring clip for backside of fork

the peddle didn't go to the floor like a broken cable or clutch fork would allow

 

i found the problem....one of the four damping spring's on the clutch plate had come out when the bent lip of steel that retains it broke off....the damping spring had come out into the diaphragm spring and that blocked the pressure plate from retracting on one side.

 

the other springs on the clutch plate are also on the point of coming free as the lips that retain them are quite badly chewed up....not quite sure what has caused this.....one thing i can think of is a small misalignment between the engine and the gearbox that is making the clutch damping springs work all the time the engine is running....the other thing i thought of is that i am running a EA82T clutch setup behind a EJ22 and the extra torque might have something to do with it

Edited August 7, 201312 yr by LPGsuperchargedBrumby

No perty normal for springs to take a beating try a legacy clutch plate in it has larger springs

No perty normal for springs to take a beating try a legacy clutch plate in it has larger springs

 right.....a legacy plate i will go a-hunting

if you don't have legacys there the than it is a liberty.

Nice work @LPGsuperchargedBrumby.

got it all back together and running....legacy clutch disc installed and new throwout bearing and pilot bearing....using the old pressure plate as that was undamaged.

 

note to anyone replacing the clutch on an EJ with an RX FT4WD DR box....pull the motor NOT the g/box, it would be alot less grief...it took about 4 attempts to get the gearbox spline to mate into the clutch spline....all while under the vehicle on my back laying in the gearbox oil that poured out when i removed the rear driveshaft.....lol i'm going to stink of spirax for weeks.

 

if i have to do it again i will be pulling the motor for sure

I have a stub shaft from old driveshaft put it in no leaks and turn in gear to line up i just used the end as a plug save hours and no oil drain nessasary

I have a stub shaft from old driveshaft put it in no leaks and turn in gear to line up i just used the end as a plug save hours and no oil drain nessasary

 

+1

hmmm i have a old bent driveshaft too.....i'll cut the end off it after work tomorrow and 'put on the shelf just in case'

Smart and cheap the subaru way !