August 20, 200916 yr I just replaced the clutch, transmission and lower ball joints in my 90/91/94 Legacy, and it shudders and shakes when I release the clutch, but only sometimes. If I burn the clutch, it doesn't shake and accelerates smoothly, but if I release the clutch normally, the whole drivetrain moves a significant distance as it shakes, and the car's motion is jerky. I have double, even triple checked my bolts, and they all are tight and everything is attached properly. Grrrr, is this normal or what? Twitch PS: Is it normal for the shifter to be able to touch the driveline when shifting?
August 20, 200916 yr It sounds like either a warped flywheel, damaged friction plate, damaged pressure plate or contamination on the friction plate... it's something in the clutch. There is a small chance that the gearbox and engine aren't aligned but this is much more rare.
August 21, 200916 yr Are all the clutch parts new? did you at least get the flywheel resurfaced if not new? Is the clutch adjusted properly? Did you get any liquids or grease or anything on the clutch disc?
August 21, 200916 yr Author Are all the clutch parts new? did you at least get the flywheel resurfaced if not new? Is the clutch adjusted properly? Did you get any liquids or grease or anything on the clutch disc? Flywheel was professionally resurfaced and all other clutch parts are brand spanking borgpwarner new. And no contamination, practically did a white glove service. Also, my pilot bearing whines. Twitch
August 22, 200916 yr Author New symptom! It shakes and there is an audible rattle or repetitive thudding when I start it. Just like when I'm starting off. And since the clutch has been used a bit more the shuddering has been reduced so I'm guessing it was just because it was a new clutch, but this new symptom is making me think I need to replace my engine mounts. But when I had it apart they seemed just fine.... Any other suggestions? Twitch PS: I did a search and came up with nothing.
August 22, 200916 yr Author You sure the flywheel bolts were tight? Yes, all bolts were tightened to spec and a little over. Your going to have to take it apart again. nipper And please explain before I do. I can't afford to tear this thing down again. Twitch
August 22, 200916 yr If it wasnt doing it before, and it is doing it after, then you have to dig back into it. There is not a hell of a lot of things to go wrong with a clutch that can be repaired externally. It sounds like it can be too thin a flywheel, a bad pressureplate, a broken spring etc. The only other thing it is worth checking is the clutch fork, make sure it is still mounted and in one piece. But the fact that that the noise is getting worse may not give you any choice but to dig into it. nipper
August 22, 200916 yr Author If it wasnt doing it before, and it is doing it after, then you have to dig back into it. There is not a hell of a lot of things to go wrong with a clutch that can be repaired externally. It sounds like it can be too thin a flywheel, a bad pressureplate, a broken spring etc. The only other thing it is worth checking is the clutch fork, make sure it is still mounted and in one piece. But the fact that that the noise is getting worse may not give you any choice but to dig into it. nipper Problem is, this car was originally an auto... So anything that crops up now may be severe, or nothing and something I just have to get used to. Like that %#@$*&^!@% squealing pilot bearing. But I did have to make a new spring clip, as I either lost one, or it never came with the donor car. It was made out of spring metal that had about the same properties as the clip. But, the shuddering is happening when starting as well, so could that be motor mounts? Tranny mounts? Twitch
August 22, 200916 yr Author Sorry nip. Its a 90 body, 91 engine, and a 94 tranny. Lets just say this thing has a Carfax rap sheet that'll make a convict look away with shame. I installed the spec clutch for a 90-94 lego, after I verified parts #'s, checking to make sure they didn't change anything on me in those years. I had the flywheel resurfaced the day I put the car back together, ummm Any more details wanted? Twitch
August 22, 200916 yr Author Yes, only one axle was swapped and that was the passenger side front. AFAIK they are interchangeable. Twitch
August 22, 200916 yr Author Nope. It goes away once the clutch is let out completely or its completely disengaged. But with the clutch completely engaged the clutch pedal vibrates more as I go faster. I thought that was something I need to just get used to... Twitch
August 22, 200916 yr You feel it in the clutch pedal with the clutch engaged? You have no clutch freeplay, check the adjustments at the pedals atc. nipper
August 22, 200916 yr Author No, no, different thing. The clutch pedal vibrates whether or not the drivetrain does. And the drivetrain only vibrates when starting the car, or starting off in 1st. Twitch
August 22, 200916 yr You have a few issues here. the clutch pedal vibrating at all timesmeans that there is some force being transmitted thorough the clutch mechanisim to the clutch pedal. The fact that it is a vibration tells me that a- something is not mounted properly in the clutch. Something is pushing up from the pressure plate, up through the fork, through the linkage, to the pedal. b- there is no clutch freeplay
August 22, 200916 yr Author You have a few issues here. the clutch pedal vibrating at all timesmeans that there is some force being transmitted thorough the clutch mechanisim to the clutch pedal. The fact that it is a vibration tells me that a- something is not mounted properly in the clutch. Something is pushing up from the pressure plate, up through the fork, through the linkage, to the pedal. b- there is no clutch freeplay Yeah, I'm pretty sure I didn't leave any freeplay in the pedal. I might need to put in some freeplay back in the pedal. But the shuddering is still there when any major force is being applied to the engine or the engine is starting to apply any force. :-\ Twitch
August 22, 200916 yr There should always be pedal freeplay Now that vibration.... are you sure its not engine related?
August 22, 200916 yr Author Fairly sure, it doesn't change with the RPMs. Only with vehicle speed. Twitch
August 22, 200916 yr Did you put the torque arm back on? Is it in good shape? Do you have all four nuts in place on the trans mount, especially the up-travel stopper with the rubber coated washer?
August 23, 200916 yr If you had trouble getting the gearbox into place you may have bent the clutch plate. If the gearbox isn't flush(something between it and the engine, bracket etc for example), it could shudder. Are the two faces tight? Did you position the driveshaft hanger correctly? Sometimes they need a little preload forward or aft to stop shudder. Could first gear have a tooth missing? If you accelerate hard, are their any noises from the box? Any "surging" sensations?
August 23, 200916 yr If you had trouble getting the gearbox into place you may have bent the clutch plate. If the gearbox isn't flush(something between it and the engine, bracket etc for example), it could shudder. Are the two faces tight? im going with those two (thats where i was heading)
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