Sysgen

Hum, clutch fork teeth maybe, can you try this, when you push the cylinder back with a screwdriver, can you move the fork at all with your fingers, if it's not broken you should not be able to move it at all.

KuHL 951

I have a hunch what you assumed was a slave failure is really a broken clutch fork that's no longer in contact with the TO bearing so it overtravels until wedged against the bellhousing. Can you push the slave rod back in after the fork is stuck? If not the push rod on the new slave has overtraveled and the seal might be damaged now.

Sysgen

He mentions in his first post that he can push the rod back in.

KuHL 951

Guess I misunderstood that. Needless to say though the fork is either not engaging the TOB or the TOB is separated if the fork travels far enough to wedge in the bellhousing. I've ruined a brand new slave by someone accidently pushing the clutch pedal when the slave was just hanging there. The shaft overtravelled and damaged the seal. Long story short his clutch doesnt engage and I doubt it's from a slave problem.

Sysgen

I also think that is the problem. He might be able to confirm this by doing what I've said before. If you can move the fork with your fingers after pushing back the cylinder then you will need to do a clutch job I'm afraid !!!

KuHL 951

Yep that would confirm it for sure. A good fork with the correct pedal adjustment will just wiggle enough to feel movement. If it travels freely it's toast. I still wonder if the fork/TOB issue was the original failure and unrelated to the slave? Hopefully he will get lucky and it's just the fork and not a slipped circlip on the TOB. A fork can be replaced without dropping the drivetrain. It's frustrating but not impossible. Like you say, if the freeplay was not readjusted when his new clutch was done it will wear out the fingers on the fork from the constant engaged condition.

Sysgen

You can replace a fork without dropping the drivetrain !!!! Wow, that must be fun ! I can imagine that you can push out the pin holding the fork in place but how do you get the fork out??

KuHL 951

Cut a relief hole in the housing. Someone posted his pics here about two years ago. Like I said, it's not impossible, but probably not fun either Personally if a shop did the clutch 3 months ago I would be giving them a call ASAP.

thekidd

I would go through everything again. Re-do the clutch bleeding procedure again. Before the slave/ master went out on you, the pedal did not do this, right? Im not a guru, but this is what I would do. Take apart anything and everything that you touched, and put it all back together. Not a long job, because you know what your doing now, but sucks to do it AGAIN.

MichelleJD

Long time, no see Kelly!

MichelleJD

I had much the same problem. Ended up being the snap ring on the TO bearing. That CAN'T be replaced w/o a new clutch job. I hope for your sake this is not the problem

Kelly Chiu

Guys thanks for the help, the clutch was replaced 2 years ago so no way to get the warranty on the work done if due to a defect, the car has been driven another 2000 miles at most in that time.

After removing the slave cylinder, the clutch release lever can be moved freely from the bellhousing hole through its full range of motion. There is no play laterally, but there is no tension so there likely is a spring that is busted somewhere.

Looks like I will have to drop the drive train to get the bellhousing off. I was going to smog the car and this happened. This will turn into a 2-3 month affair as I can work on this sporadically. Any tips on a turbo clutch job? I have been off the boards and not driving the car because I just finished managing the construction of a large hotel. Working 110 hours a week for 8 months and another 60-80 for the 1 and half years before that of course got in the way of things. Its kinda funny that I have not been on Rennlist for awhile, but it still feels the same. Good deal overall.

KuHL 951

Sorry to hear the news but at least you know what it is now. Either the fork failed or TOB came apart. At least you 'only' have to get as far as removing the bellhousing and not do clutch work. Good luck, hopefully you can get some local volunteer help some weekend like this RLister: Clutch Party