I have been fighting some noise and clutch chatter for around a year. Recently I blew the slave cylinder. Replaced it and found that the clutch master was also leaking. I made the decision to replace everything at this point. New clutch, pp, throwout brg, pilot brg, resurface flywheel, new clutch master and slave cylinder. I've done this work many, many times and everything went well. However, when we fired up for a test shifting the trans would not go into gear (clutch was not disengaging).

The required travel of the slave cylinder is .57" and I was getting .61" of travel. Everything was bled well and there was no air in the system. I removed the bellhousing boot and was able to watch the fork travel and everything looked normal. I did forget to include that I have a lakewood scattershield with an adjustable ball. I have adjusted the ball to get a maximum travel of .63". The car still would not shift.

Then I thought I would experiment a little further. I put a 3/8 washer in the dish of the throwout fork in an attempt to get a little more travel out of the slave. We are now moving the slave .66" and the car shifts just fine. Now, of course, I can't leave it like this.

I have checked everything I know to check. The only suggestion that has been given to me that I haven't looked into completely is this. This is the third clutch in this cars history and every time the flywheel has been resurfaced. A very good mechanic has suggested that the flywheel has just had too much taken off over the years and it's time for a new one.

I'm open for suggestions and willing to give anything a try at this point. Hopefully somebody here can give a little help. Sorry for such a long post.

Les

 

You might be able to solve your problems with a longer throwout bearing.

 

Thanks Tom. I had forgot to mention in my post that I had given that some thought. That is a remedy that we used to use in the old days along with different angle throwout forks. It's definitely a cheaper fix than a new flywheel.