idosubaru Posted March 28, 2006 Share Posted March 28, 2006 i installed an engine in an 87.5 XT with all new clutch stuff. bolted new flywheel and clutch to the motor. new throwout bearing and clips. slid motor onto transmission. i installed the clutch cable and the pedal just goes to the floor and doesn't return? this was the first time i've reinstalled an engine in a manual transmission. is there any trick or just slide it onto the output shaft of the trans? somethign doesn't feel right i hope i'm not pulling the motor back out! Link to comment Share on other sites More sharing options...
Subarian Posted March 28, 2006 Share Posted March 28, 2006 Did you get the throwout bearing onto the end of the clutch fork? Is the fork seated properly in the bell housing? Is your return spring attached? It's pretty straighforward- align the clutch plate with the input shaft on the trans and mate the trans and engine. I just noticed you didn't mention the pressure plate. If that's missing, the clutch won't return and you're going to pull the motor again. Link to comment Share on other sites More sharing options...
idosubaru Posted March 28, 2006 Author Share Posted March 28, 2006 i installed the flywheel, clutch and pressure plate while using the clutch alignment tool. i attached the throwout bearing to the clutch fork with new spring clips. i hope i'm not pulling this motor out again, i'll use my rationed number of 4 letter words for the month. i do not have any return spring - what is that? i know what it is, but don't recall seeing one. does the "hill holder" cable provide that function? i've heard of people removing those, i was plannign on the same. maybe i should install it for now to get the return spring function back. Link to comment Share on other sites More sharing options...
Subarian Posted March 28, 2006 Share Posted March 28, 2006 The springs in the pressure plate should be enough to push the clutch out to where it engages. The return spring pulls the fork back a little more so the throwout bearing isn't riding on the pressure plate. It's located at the top of the bellhousing. There should be a little eyelet on the clutch fork by the cable and another one on the bracket on the top two bolts on the bellhousing. That's where the return spring goes. You can choose a softer or a stiffer spring to give the clutch pedal the feel you want it to have. Does your clutch engage when you let off the pedal? You might just need to adjust the clutch cable. Link to comment Share on other sites More sharing options...
idosubaru Posted March 28, 2006 Author Share Posted March 28, 2006 i noticed the eye for a spring...i'll look into getting a spring for that. when i let off the pedal it just stays on the floor, it doesn't come back up. i can't feel anything engaging, nothing about it feels right. press down and it falls to the floor and doesn't come back up. i'll check adjustment too. being my first clutch install let me verify this: first the flywheel bolts to the motor? then the clutch basically sits inside the flywheel...use the alignment tool and it sits inside there right? i hope i didn't screw that up. then the pressure plate bolts to the flywheel. what holds the clutch disk in place? i bet i'm pulling the engine again.... Link to comment Share on other sites More sharing options...
azsubaru Posted March 28, 2006 Share Posted March 28, 2006 If it's a hydraulic clutch - fluid? Link to comment Share on other sites More sharing options...
Subarian Posted March 28, 2006 Share Posted March 28, 2006 Yes, the flywheel bolts to the crank, and the pressure plate bolts to the flywheel. The clutch disk is held in place by pressure between the surface of the pressure plate and the flywheel. When the pressure plate is bolted to the flywheel, you shouldn't be able to move the clutch disk- that's why you need the alignment tool to get it in the right position before you tighten the bolts. Then the throwout bearing slides onto the transmission input shaft, and the input shaft goes through the clutch disk. When the pedal is depressed, the fork moves the throwout bearing against the fingers on the pressure plate, which releases the pressure that locks the disk between the flywheel and pressure plate, allowing the clutch disk to turn independently of the flywheel. One more thought- is the pivot pin in the clutch fork? Link to comment Share on other sites More sharing options...
Subarian Posted March 28, 2006 Share Posted March 28, 2006 If it's a hydraulic clutch - fluid? No, EA82s don't have hydraulic clutches. The fluid in the hydraulic clutch basically fulfills the same function as the cable in a mechanical linkage. It's comparable to hydraulic brakes compared to your parking brake. Link to comment Share on other sites More sharing options...
idosubaru Posted March 28, 2006 Author Share Posted March 28, 2006 subarian..... thanks for the input. fork is on the pivot for sure. now i'm wondering if i installed the clutch disc properly. it seemed to just "sit in place", seemed very easy to do. i knew i should have verified ahead of time. i used the clutch tool to hold the disc centered in place while i bolted the flywheel up. is this tricky or could i have messed it up? it seemed way to easy, like the clutch disk was just sitting in there and the tool did little more than hold it centered? i think i'm about to hate 5 speeds more than i already did. automatics rule. ha ha, thanks for the feedback. i'm hoping the cable is mal-adjusted. Link to comment Share on other sites More sharing options...
Caboobaroo Posted March 28, 2006 Share Posted March 28, 2006 I had this sort of problem before as well. Check inside the car where the clucth cable comes through the firewall. I know on my RX now, and a few other EA82s that I've worked on, there's a spring down there and if its not setup right, it'll go to the floor and not return. Also, did you check the clutch for as well? I know that where it pivots will sometimes break and it will do the same thing. If the clutch fork didn't break, make sure the pivot is lubed up really good to prevent it from wearing and breaking. Link to comment Share on other sites More sharing options...
idosubaru Posted March 28, 2006 Author Share Posted March 28, 2006 i cleaned all the old gunked up dirty grease off the clutch fork and greased up the pivot really well. followed the FSM as best as i could except i didn't use the special "molybdemunmbidamumm grease" it suggested, i just used regular grease at the suggestion of others. i'll check the pedal/cable. (mucho hopeful this is the case....) thanks! Link to comment Share on other sites More sharing options...
Subarian Posted March 28, 2006 Share Posted March 28, 2006 I've been doing a little reading since this thread started. It seems the return spring isn't necessary (in theory) on models equipped with the hill holder. I have one on mine, though. But in any case, the springs in the pressure plate should be pushing back against your pedal. Link to comment Share on other sites More sharing options...
idosubaru Posted March 28, 2006 Author Share Posted March 28, 2006 that's what i got too reading through info - i don't have the hill holder installled, so maybe (hopeful but doubtful) that's the issue. is the clutch disk install really that simple....use the tool to hold it centered, but otherwise it's just "laying in there" so to speak as you bolt the pressure plate on? uh-oh...i wonder if i jacked this up - i used an EA82T flywheel and XT6 clutch and pressure plate. is that a problem? Link to comment Share on other sites More sharing options...
Subarian Posted March 28, 2006 Share Posted March 28, 2006 I don't know about the XT-6 clutch, although I remember reading that they'll work. The clutch should have fit loose when you aligned it with the alignment tool. Once you bolted the pressure plate on, it shouldn't have moved. Link to comment Share on other sites More sharing options...
idosubaru Posted March 28, 2006 Author Share Posted March 28, 2006 well that makes me feel a little better, but i can't recall it being tight or not once the plate was bolted on. memory fails me on that one. would a motor swap cause the cable length to vary? i went from turbo to non-turbo. doesn't seem like it since the block is the same and i didn't touch the trans. Link to comment Share on other sites More sharing options...
Subarian Posted March 28, 2006 Share Posted March 28, 2006 No, the cable length should be the same. Try pushing on the clutch fork. If you push it (or pull it) and it springs back, that's the pressure plate. If that happens, look at your cable linkage. Link to comment Share on other sites More sharing options...
idosubaru Posted March 28, 2006 Author Share Posted March 28, 2006 thanks much, i'll check tonight and post back tomorrow. Link to comment Share on other sites More sharing options...
idosubaru Posted March 29, 2006 Author Share Posted March 29, 2006 subarian, thanks for all the help. i needed the hill holder mechanism attached to provide the spring return for the clutch. worked perfect and i got to drive it around some last night. needs a little adjusting to come back a little smoother, but worked great. SO STOKED THE MOTOR DOES'NT HAVE TO COME BACK OUT!! looks like the spring on the clutch pedal assembly provides assited for "pushing down" the clutch pedal and the hill holder cable provides the return spring action. there is a small hole on the top of the clutch fork obviously for a return spring as well on non-hilder holder equipped soobs. although one of my XT6's has both - hill holder and a spring, but it's definitely not a stock spring set up. thanks! Link to comment Share on other sites More sharing options...
Subarian Posted March 29, 2006 Share Posted March 29, 2006 You're very welcome. I'm glad the motor didn't have to come out again. Link to comment Share on other sites More sharing options...
idosubaru Posted March 29, 2006 Author Share Posted March 29, 2006 You're very welcome. I'm glad the motor didn't have to come out again. WOOO HOOOO!!!!! mucho thanks! i'll buy you a happy meal next time you're in maryland! Link to comment Share on other sites More sharing options...
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