LarryD

Just got my T5 back in the car.. I had it rebuilt back in May in Seattle but just got it in the car at Xmas.. Unfortunately I am now in Denver with it and finding that if I accelerate and shift fast from 1st to 2nd it will grind going into gear.. A slower shift and no grinding.. All other gears and shifting both up and down seem fine.

Any ideas?

sofakingdom

iTrader: (1)

Clutch problem.

What did you install; a pilot bushing, or a pilot bearing?

LarryD

Yup, surfaced flywheel, new pilot bushing, new clutch disk, new pressure plate, new throw out bearing.. That said, the clutch is real close to the floor... I have tried slamming the clutch pedal to the floor real fast then shifting fast but that doesn't seem to help... Wondering if the guy that rebuilt it screwed up the synchro for 1/2...

sofakingdom

iTrader: (1)

Prolly not. Not much to "screw up" there.

Sounds like you should check this instead.

LarryD

I watched that pretty close so pretty sure it is correct.. I was able to mate the transmission to the bell housing while it was out of the car so wasn't really fighting with it.. I may pull the clutch boot off and check that again... Wondering if maybe I need to replace the clutch hydraulic cylinder.. Oh, just thought I better check the clutch reservoir for fluid level.. Guess I will do that tomorrow...

FormulasOnly

What trans fluid are are you using?

LarryD

I believe it was Dextron III ATF....

MoJoe

iTrader: (5)

Looking at Sofa's picture, that is a likely cause.


If not that, my $.02 is: the amount of material taken off the flywheel opened clearances, which goes with your clutch releasing with the pedal near the floor. This means simply: Your clutch is not releasing all the way when you shift quickly.
Search at Summit for: Flywheel and Flexplate Shims and Spacers.

LarryD

Now there is a thought that hadn't come to mind. The flywheel is the original from the factory off my 3.1L when I did the 3.4L swap. The car has going on 450,000 miles, hence the rolling restoration. It has had multiple clutches so let's say that it has had the flywheel resurfaced 3 times. As you point out, my clutch throw at the slave cylinder has been getting shorter. Now, I remember that when I replaced the master/slave clutch assembly several years ago, it came with a nylon strap and cap on the end of the slave shaft.. After install you had to cut the straps releasing the shaft. But, the nylon cap was to stay in place between the shaft and the clutch arm as a bearing..... I didn't pay attention (or remember) that cap/bearing when I disassembled and reassembled the slave to the bell housing... That would have shortened the throw even farther.. Guess I need to round up another cap/bearing for the slave shaft and see if that solves the problem...

Thanks for that idea... That sounds like a strong possibility for resolution...

sofakingdom

iTrader: (1)

Nope, that doesn't "change the throw". "Throw" = where it finishes, minus where it starts (i.e. how far it moves); how long it is, doesn't affect how far it travels. In fact, I don't believe I have EVER taken a car apart, and found that little piece still in there. Don't waste your time on that.

LarryD

Ok, so time for an update... I have access to a lift this weekend so on Saturday going to pull the trans and bell housing.. I have in hand a new flywheel, new flywheel and clutch bolts, and a new master/slave clutch cylinder assembly to put in... I have a vibration at 2200 and 3800 RPM so hoping this eliminates that as well as the 1/2 grind...

LarryD

So, I pulled everything apart and put in a new flywheel and put in a new clutch master/slave assembly... No change with the grinding on fast shift 1 to 2.. Vibration feels like it is better... I guess that means something going on with the synchros...

Interestingly, the new clutch master/slave puts the pedal higher than the brake and the clutch engages now about 2 inches from the floor.. With the old assembly, it engage just about an inch from the floor and the pedal was pretty even with the brake.. And, of course, the white plastic clutch rod lock bushing broke changing the clutch master...