installed twins now just grind grind grind

monterx7 · March 05, 2011, 04:44:45 PM

adjusted pedal both in and out with no luck at all.......im at a complete loss

pdtaylor18 · March 08, 2011, 01:58:35 AM

Lets look at this logically:

1. Was the old setup ok ie clutch and gearbox working as it should
2. You installed a twin plate clutch but it grinds
3. Replaced Clutch slave cyl
4. Replaced Clutch master cyl
5. Replaced pilot bearing
6. Replaced clutch to standard
7. Clutch adjusted and bled

So whats left:

1. Clutch Fork
2. Gearbox oil
3. Blockage of somesort in feed line? does it bleed well?
4. All the times you bleed it do you get lots of air indicating a leak or is it relatively air free?
5. One other thing to check, get someone to press the pedal and then you check to see how far the clutch fork is moving as viewing from above, make sure you get good movement. Check that the little piston in the slave is the correct length. The slaves vary from TII to EGI but only in the offset of the mounting holes but i am not too sure on the piston/plunger thing itself. they do look the same internally.

monterx7 · March 08, 2011, 04:53:45 AM

Quote from: pdtaylor18;747549Lets look at this logically:

1. Was the old setup ok ie clutch and gearbox working as it should
2. You installed a twin plate clutch but it grinds
3. Replaced Clutch slave cyl
4. Replaced Clutch master cyl
5. Replaced pilot bearing
6. Replaced clutch to standard
7. Clutch adjusted and bled

So whats left:

1. Clutch Fork
2. Gearbox oil
3. Blockage of somesort in feed line? does it bleed well?
4. All the times you bleed it do you get lots of air indicating a leak or is it relatively air free?
5. One other thing to check, get someone to press the pedal and then you check to see how far the clutch fork is moving as viewing from above, make sure you get good movement. Check that the little piston in the slave is the correct length. The slaves vary from TII to EGI but only in the offset of the mounting holes but i am not too sure on the piston/plunger thing itself. they do look the same internally.

1. the old setup was fine (just needed replaced)
2. correct
3. replaced throwout bearing twice and acouple pilot bearing
4. replace clutch with standard
5. replaced master/slave cylinders
6. bled system
7. adjusted pedal

1. im trying to source a clutch fork now. will buy from mazdatrix if i cant find one.
2. the gearbox has new oil, will change on the next gearbox pull
3. clutch sys does bled well.
4. the only time i had any air was replacing cylinders
5. ive been trying to find out if there is a set distance that the fork has to move. so far no luck. but will measure next time i can borrow another set of hands.

since have to keep pushing the car to the shop and find a parking spot then push it back out, ill wait till i get a fork(or gearbox) till i get back underneath it. the shop has lifts so much easier to do the work. something else a friend of mine suggested was to make sure the throwout bearing is making good even contact on the pressure plate. im open to any ideas that will help get this car back on the road.

thanks again pete. i appreciate you still kicking around my car issues and trying to help.

pdtaylor18 · March 09, 2011, 09:17:46 PM

One thing else, when was the oil changed last? was it the right oil? Wrong type of oil can cause a whole host of gearbox/clutch problems but none as extreme as yours but with so little else left to check then its worth a try for what it cost.

monterx7 · March 10, 2011, 08:45:58 PM

oil got changed out the first time we pulled the gearbox...and it is the correct oil weight...i sourced out another gearbox and fork and what not. now just got to wait for the lifts to be open again at the auto hobby shop

monterx7 · April 06, 2011, 09:11:27 PM

and still fooked up...........

i swapped out a gearbox and still have the exact problem. we installed the new/used gearbox without oil and it worked. i didnt drive the car around or let it run for very long at all. i moved the car forward and rev acouple times just a few feet each way. so figured it was fixed. put oil in the gearbox and this time it didnt work at all............

maybe the oil im using?

?? does that even sound right???

well here is what im using

only stuff i can get my hands on thats close to where the car is.

any thoughts?

steve garbutt · April 06, 2011, 09:32:15 PM

You need to see how much travel you have on your slave cylinder.
If there is enough travel (im sure someone here with the same setup will measure it) then you can count out from the pedal to the slave.

The reason why the gears are grinding when running but not binding when switched of is that your engine is turning your gearbox.

If you have ruled out the pedal system by measuring the travel on the slave and clutch by fitting a stock on then there is only the pilot bearing left.
I have had the same problem on 3 FD (but not fb\'s) in the last 2 years and they all ended up being the pilot bearing.

steve garbutt · April 06, 2011, 09:32:51 PM

or a bent fork

monterx7 · April 07, 2011, 08:49:50 AM

ive tried 2 different forks, pivot balls and several throwout bearings. even swapped out master cylinder and slave with new ones from mazdatrix. i doubt im installing the pilot bearing wrong, or maybe i am. ill look into measuring the travel of the slave...

steve garbutt · April 07, 2011, 12:59:08 PM

If you have covered everything else then it will be your slave cylinder, the slave wouyld have been the 1st thing i would have swapped out.

grinder · April 07, 2011, 01:30:32 PM

i think hes done that steve :

Quote. even swapped out master cylinder and slave with new ones from mazdatrix

steve garbutt · April 07, 2011, 01:32:21 PM

Well there isnt anything left :S

BlitzBoy · April 07, 2011, 01:34:37 PM

I dont know if you have this on FC, but there is pipe from the brake Servo resorvoir on the FD that feeds the master clutch cyclinder with fluid, sometime these pipes perish causing and collapse inside causing problems, eg air into the clutch hydralic lines and loss of pressure, I assume when you bled the system there was no air and the rate of fluid being purged out of the bleed nipples was of good force indicating the pipes are not partially blocked or corroded in any way

no_boingers · April 08, 2011, 08:26:04 AM

Have you checked you are getting full travel on the clutch pedal? And that *it* isn\'t bent? (My nephew managed to bend his clutch pedal once by stomping on it in his DMs!).

monterx7 · April 08, 2011, 07:29:08 PM

yeah i adjusted the pedal to make sure i was.

i keep going over everything in my head cause i know its gotta be something seemple and will slap myself when finally figured out