New clutch slipping after install

[Beater91]

I have a '91 FWD non-turbo Legacy. I've had it about 5 years and my clutch finally went out.

While I had the motor pulled I did:
-New clutch
-New pressure plate
-New throwout bearing
-New bearing that rides in the flywheel
-New rear main seal

I have a new clutch cable on order.

So, my issue is that after I put it all back together and started it up there was a horrible noise coming from the area of where the bellhousing meets the engine. I've tried adjusting pedal freeplay a million different ways, and I can get the noise to be not so bad.

However, even with the car in Neutral and the regardless of the clutch pedal being pressed, it still happens. After starting, when I release the pedal the rpms drop and the noise quiets some. I am thinking that the clutch cable is probably just stretched from all the years of use, and hope that replacing it fixes my problem, because I've run out of freeplay adjustment.

Anyways, I figured I would get everyone's opinion while I wait for the new cable to arrive. Thanks in advance

[Legacy777]

Welcome to the BBS.

I suspect something did not installed back the way it should have. The clutch cable really shouldn't have any bearing on the clutch, pressure plate, etc.

Did you take any pictures during the install that you could share for us to look at?

[Beater91]

Pictures of the new parts installed is about the only thing I didn't take a picture of unfortunately. I know I have the proper side of the new clutch facing the flywheel. The only thing that I can think of is that possibly the throwout bearing was put on incorrectly. My friend did that part while I was doing something else.

[Legacy777]

Ok, well you may need to try and look down the access port of the bell housing where the clutch fork goes in to see if you can see anything that doesn't look correct.

[James614]

If you can get a hold of a bore scope, they work magic for giving a peak at the release bearing to make sure its engaging the clutch fork and pressure plate properly. Of course more than likely you will need to pull the trans (or engine) back out regardless

[Beater91]

I'll take a look at it tomorrow and see what I come up with. If I end up having to pull the motor again, so be it. I am sure it will go a lot faster the next time around than it did this last time.

Thanks for the help guys, I'll keep you posted.

[Beater91]

So I think I found the source of the problem... a pretty big screw up on our part.



We somehow got that piece of metal stuck between the bellhousing and motor...and torqued it all down. So this was rubbing on the flywheel

As seen here:



You can see where it has brightened up the sides of the teeth from the rubbing.



I'm pretty sure that was the source of the horrible noise, however I have a question about the clutch fork.

Right now it wiggles real easy, and I managed to get this picture of it.


Is this normal or is that little tab suppose to be engaging something?

Another angle.

[rallyak]

The fork looks good, it will be loose. Make sure both clips are on the throw out bearing, and that bent shield can be removed. I haven't had one on my car since I bought my car.

[James614]

I've been paranoid about accidentally catching that guy when putting my trans back in. Not nearly as bad as it could have been.

The clutch fork looks normal to me. Did you drive the car to verify clutch slip or did you assume the noise was the clutch disk?

[Beater91]

I drove it probably about 3 blocks and it drove nice. I was afraid to drive it any further because of how bad the noise was. What I was thinking was slip/engaging in neutral was probably just that metal rubbing on the flywheel causing the car to eventually wind down and stall out.

I took a video of just how sloppy the clutch fork feels. Just seems kind of weird to me that there would be that much play in it naturally. I didn't have time to upload it earlier before work, but I'll upload it now.

Thanks for all the help guys.

[Beater91]

Here is the video I took before I discovered the bent shield rubbing on the flywheel.

[rallyak]

That's play is normal.

[Beater91]

Alright, thanks for the clarification. Its the first time I've ever had the two apart, so I'm still learning. Think its time I start putting it back together

[Legacy777]

I think you'll find the clutch feel to be better without the shield in between the trans & engine. You may need to readjust the clutch cable.

[Beater91]

Yeah, its much nicer now... the car actually moves now! Been driving with the new clutch for a week or so. Happy to report everything is going well.

[Legacy777]

Glad to hear everything's working well.