Ok, I have done too much in 3 weeks for me I guess. zzz I replaced the clutch, rear struts, and the ignition switch in my 85 Brat.

 

My last braincell burned out after realizing that my Chilton manual screwed me up telling me I had to drill out the bolts holding in the ignition switch, then I had to figure out how to get into that lovely "large" space to install new bolts from inside the tilt-wheel housing.

 

Now, I finally have everything done, and notice that the clutch feels REALLY soft (like it's not engaging at all).

 

I went ahead and tightened up the clutch cable (got a new one of those too) and now I have had to make it so I have zero play in the cable, and I can just get it into all the gears, however reverse is nearly impossible.

 

I'm sure there is something really simple I am missing, but like I said, I burned out my last braincell, so I need to borrow yours!

 

Oh and happy fourth! (insert fireworks icon here)

 

Thanks in advanced!

 

P.S. I had the flywheel turned, and did the "XT6 clutch upgrade" don't know if this might have anything to do with the problem ...

Edited July 9, 200916 yr by FlyB0y

EA-81 right?

 

the clutch material is thinner on those then the EA-82

 

 

More info about your car would help too. a/s/l (ea-81/82)

LOL yeah, but that takes more braincells!

 

Ok, it's a 85 brat EA 81 with the 5spd D/R tranny from an EA82 car.

 

I'm probably going to find out it's just something stupid like having to have the cable extra tight during the break-in of the clutch? Or maybe when I had the tranny out I some-how changed the linkage putting it back in?

 

This is my first time solo doing a clutch in any vehicle so don't discount the possible bone-head things I could have missed. :-p

Well, I think I may have regenerated a braincell or 2 over-night, looks like the linkage was binding, I have a "custom" 2-piece bracket that holds the linkage in the right spot (where the plate has the pivot for the stick shift and this 2-piece place has a rubber cushion that normally holds them together) Looks like 4th and reverse have the most trouble binding.

 

Now I can get it into all gears, but 4th and reverse are still a real pain.

is that a clutch thing or is your linkage binding up on the wire harness connectors for the switches on the tranny?

 

I just put a d/r in my s/r car and had to remove and re-install the wire harness... clearance is an issue on mine

is that a clutch thing or is your linkage binding up on the wire harness connectors for the switches on the tranny?

 

I just put a d/r in my s/r car and had to remove and re-install the wire harness... clearance is an issue on mine

 

Hmmm, that is a good thing to check, hadn't though about that, could very well be my issue too.

 

I am still having difficulty with 4th and reverse, I gave the cable as much slack as I could, and it still seems tight, but thank you for the tip, I will take a look.

Well, the wires are definitely not an issue, I have tons of clearance, and no wires near the linkage.

 

If anyone has anything else to clue me in on why I might have difficultly getting into just 4th and reverse.

 

It seems to drive just fine, went on a good 40 min. one-way trip to my brother's house in Newberg now the hills on 99W are easily conquered while staying in 5th (no more slipp whoo-hoo!) it stills bogs a bit if I don't have a good running start, but before I would have to drop to 4th AND floor it even if I had a good start to keep from slipping.

Well I finally found the problem, I had a bolt in backwards (had it bolt head up instead of bolt head down) and this bolt sticking out between the shift linkage and trans rod was digging into the side of the lower rod, thus making both 4th and reverse hard to put into gear.

 

I only noticed it because I started to see a nice new gouge on the freshly painted shift linkage rod.

 

At least now I know it's not something else going on.