Hey guys when i got the new clutch for my ea81 brat i went to put it on, and it's identical to the old one, and noticed there was about an 1/8th" gap and when i tightened the bolts down the fingers went flat and i knew it didn't look right but i was told by a few old mechanics that it was normal and would be fine, i finish the installation today and the car rolls while in gear, so what happened that the new clutch cover has that much of a gap, i mean yeah it's a new clutch disk but its not an 1/8th" thicker and yes i put the old cover on and it was the same, HELP!!!

Sounds like the flywheel was not machined correctly. These cars have a stepped flywheel, so the pressure plate mounting surface must have the same ammount of material removed as the disc mating surface. are you sure there isn't some other install issue like clutch cable adjustment or throw-out bearing or fork not seated correctly?

Throw out bearing and fork were good and the cable isn't even hooked up yet, i didn't have the flywheel machined.

A backwards disc would cause other problems, or so I would think but thats my next thought.

I thought that at first when i was putting it in but when flipped around the disk sticks out like 3/4" from the flywheel face.

So the disc is still loose and just floating around when you tighten the cover bolts? What year is the car?

No the disk seemed to be tight when i put the cover on, its an 84 ea81 brat. I need to pull the motor back out to really diagnose this but its raining and will continue to do so for the time being so i oly get small windows to work.

Im confused about the 1/8" gap. Where is that? We agree it doesnt matter you have some work to do anyways. When I had parts issues it was adjustment problems not a lack of engagement.

It was between the clutch cover and the flywheel where they meet and bolt together.

Alignment pins holding it up? Does the 1/8 gap between the cover and the flywheel disappear when you torque the bolts down (cover mounting flat and flush)? Its under spring pressure so there will be resisntance as you tighten it up. Thats how the clutch is engaged.

It was just at the pins, yes it disappears and is under pressure, but the fingers are flat, not bowed outward, as if the throw out bearing was pushing on them but it was still on the hoist.

ISo the disc is tight and release fingers compressed due to proper contact or sandwiching? From what you are describing it sounds like the issue may lie else where in the system. Whats the play like when you jiggle the fork? You should be able to feel when the fork/TOB assy touches the release components but not tight or stuck. If that feels good, Ide hook up the cable and work the clutch. This may aide in your diagnostics, Im assuming the engine is bolted to the trans and mounts at least resting on the frame.

Yeah i can feel the fork assembly moving and when i did hook the cable up i had to bottom out the adjuster before the cable even began to get tight and the pedal was still loose but it did push.

And yes the engine is 99.98% installed

Alright if i did this right first two pics should show clutch cover with bolts loose no tension

And these two should show it bolted down and the fingers flat

Thoughts?

Only thing i can think is the clutch plate is too thick pushing out on the pressure plate as it bolts down, I'll see if i can come up with a micrometer to measure the thickness.

This

http://www.ultimatesubaru.org/forum/topic/30080-flat-pressure-plate-springs/?fromsearch=1

Is the only thread i can find that has the same thing happening that i do but his proplem was a nissan clutch the hub was hitting the flywheel,

My clutch hub isn't hitting the flywheel.

You sure this kit is an exact match to the parts removed?

 

1: how does the disk fit in the flywheel?

2: long shot - but do the splines of the disk match the splines on the trans?

3: what prompted you to replace the clutch?

The disk fits in the flywheel good

The splines match

I was doing an engine rebuild and the old clutch was worn almost to the rivets

 

This is the kit from rock auto for my car

BRUTE POWER MU476801

 

4WD; Diaphragm Style; 8-7/8 Inch Clutch Diameter; 21 Tooth Spline; 7/8 Inch Input Shaft Diameter [Wholesaler Closeout - Private Label Pkg. - 30 Day Warranty] (Only 5 Remaining)

 

The pressure plate/clutch cover is identical to my old one and the clutch disk seems to be also only difference being that the old one is completely worn and the new one is new.

But looking at the box its a napa clutch set part no. 1115003

With a sticker on it that says replaces brute power mu476801

This kit is also the 8 7/8" set as thats what was in my brat

Just checked napa's website to make sure this set is right, their site says 1115013 is the right one for my brat, that would be the 7 7/8" set and I've already had to return one of those i bought on amazon, so no help there.

Wholesaler closeout indeed. Going on intuition and imagination Ide say you have a parts issue. Not alot of possibilities here. Weather its a defect or compatibility issue (not uncommon in the ea81 world) you may be looking for a new set. Its odd they appear the same as what was removed. Did put a caliper on the disks?

IIRC the fsm has the specs for disk inspection, Looking online at rockauto they list several options but the pics all look the same for the 8-7/8. Take your kit with you to the first auto parts store that says thay have the right kit for your car instock. Bring your caliper and compare your kit to the kit they have.

Edited November 2, 20169 yr by ihscout54

I haven't measured the disks yet, don't have calipers 30mi to stores lol, but can't seem to find what the thickness should be.

My FSM says 8.5mm (.335"). it also says woven asbestos for the material. It may have little value when being compared to an aftermarket kit.

Well i feel like an spardnubbin for wasting your time, when i started taking the motor out i told my wife to pull the ebrake...... she pulled the 4wd lever into neutral....... so the input shaft was just spinning doing nothing, about to put motor back in, thank you ihscout54 for all the suggestions and help, excuse me now I've got a hole to dig....... just kidding.