I just rebuilt an 85 GL. Put a 94 Wagon 1.8 turbo with wiring harness in it and an 86 GL Transmission. I put a brand new clutch plate, flywheel off the 85, and new bearing in it. So now my clutch doesn't seem to engage and my adjuster is bottoming out. What the heck did I do wrong? 

Edited November 22, 201312 yr by dherzog1984

hi,

 i have seen it that folks put the clutch disc in backwards causing the disc springs to bind on the flywheel,, the disc is basically flat on one side and the springs a little offset on the other side,, the offset side has to go toward the pressure plate, flat side to the flywheel.

 not saying this is the problem but it does happen.

94 Turbo 1.8? Not from the U.S then.. but it shouldn't matter.

 

Like ruparts said, could be a backwards pressure plate.

 

But just making sure, the 85 trans you took out was 4WD and you're putting in an 86 4WD trans, correct? Did you replace the cable?

No i didn't replace the cable, I was thinking of stacking some washers on it, kinda give it more adjustment room to see if a cable would be all I needed. I didn't install the plate backwards, I know that much at least.

Are all of the parts of the cable on the fork still there (like the cone seat, ect)?

 

How "not engaging" is it? close? no where near it?

Yeah all the way down to the protective rubber covers on both sides of the fork. I'm grinding gears if I attempt to put it in gear.

A bit obvious, but is the clutch cable outer sheath secured so it can't move?

 

I've once had one of those springs in the clutch plate come out & get jammed between the pressure plate & clutch plate. But this is extremely rare and due to a manufacturing fault

Throw out bearing? 

 

Got it in there?  Correctly?

 

Dumb question just makin sure

Did you have the old bits to compare against the new bits ? I did, and still picked out the wrong bits and ended up with similar problems you have described.If you send ten bucks to my PO Box,I'll send you the answer ......gonna have to start that in here, but modernise it a bit and go paypal

 

You know, I was playing with 225mm clutches from both EA81 and EA82 and managed to shove an EA82 pressure plate in 225mm with an EA81 clutch disc on an EA81 225mm flywheel. If it was not for the fact EA81 used 23mm step and EA82 pressure plate was happy to work with a 21mm step - that 2mm difference gave me cause to time engine out in 45 minutes and back in and running with a 23mm step pressure plate in 90 minutes.

 

I don;t think a friction plate can go in wrong way on these as crank bolts hit the plate ?

 

I think the hole you see in the middle of all th spring fingers differs between EA81 and EA82 225mm pressure plate so bearing may touch in different position, less leverage ? Don't shoot me if I am wrong here .....

Edited November 22, 201312 yr by jono

I will have to do some research on that, just find it hard to believe only a couple millimeters would make that much of a difference. Blows my mind... looks like I will have to drop the tranny again to find out.

You problems are a blessing in disquise.  The GL transmission is a 3.9 gear ratio, however your rear turbo differential is a 3.7 gear ratio.  Had you been succesful at assembling everything, then your back end would want to drive faster than your front end.

You problems are a blessing in disquise.  The GL transmission is a 3.9 gear ratio, however your rear turbo differential is a 3.7 gear ratio.  Had you been succesful at assembling everything, then your back end would want to drive faster than your front end.

 

I think on;y the engine is turbo.

 

The car is an 85 GL so 3.9. should be fine.

Yeah car is an 85 GL, tranny came out an 86 GL just the engine is the turbo. It says my gears on the rear dif is 3.90 so I should be ok there.

http://www.rjes.com/html/clutch_types.html does this make sense to you? I'm confused on how I can even tell the difference lol. I suck at this.

Most of that doesn't really apply.

 

You have a 225mm push type. 

 

It is possible though that you got a late EA81 (Brat, Hatch) clutch set.  and with the new flywheel who knows if that's EA81 or EA82.

 

You go the part#s of the stuff you put in?

Yeah somewhere, I will have to dig when I get home. The flywheel came off the 85GL cuz the 86 was an automatic.

kf680-02 Is the clutch kit I put in it, but It doesn't tell me the MM.

or if you say 'new' flywheel - wasn't new as in fresh off the shelf ? Did you have it machined ? It would be up to the machinist to check what the step should be, should machine both planes/levels to maintain spec. And, when others are fiddling and need to use a clutch of one step may have flywheel machined to suit clutch not specs - they might have been supplied wrong clutch on Christmas Eve, or only had one choice of clutch in the boondocks/ past the black stump/ back o' Bourke and ingenuity came into play to stuff you around years later.

 

Those paper clip looking clips on the clutch release bearing sometimes come out broken or missing and not been a cause of any noticed problem.

Others also tinker with the adjustment of the pivot ball the fork works on

The Flywheel isn't new, Came off the 85GL engine. Pins on the bearing are in good condition. Good Idea I will check the fork, see if it maybe settled in the wrong spot or something.