As stated similarly in another post:

I have a T-5 on my 91 RS.

Occasionally, randomly, when i press the clutch in I hear a chattering as if the clutch isnt fully disengaging. I replaced the slave and master cylinders, and checked all the lines, and I am getting the minimum .57 inches of clutch fork travel required for my 5.0 TBI car. Another problem is that sometimes I cannot get my car into 4th gear, to do so i have to take the shifter to the 2nd gear path, then 3rd, then it will go into 4th
What else could be the problem?
-not enough bleeding?
-worn throwout bearing?
-worn Pressure plate?
-worn driven disc?


any help and insight would be greatly appreciated. I will answer any questions you have if that will help you give me a more educated answer.

BTW, I replaced the driven disc about 3 yrs ago with a RAM, although that is all i replaced and did not have the flywheel turned.


-blain

 

Sounds like your pilot bushing is non-existent. It's a 75¢ part that has caused many a $450 clutch job to fail to fix the malfunction. It is in the end of the crankshaft.

 

RB

Pilot bushing you say? that's the first time I have ever heard that, and im not discounting the possibility, but most every one else responds with a worn Throwout bearing.

Could you tell me why you think its the pilot bushing between the flywheel and the crankshaft?

-blain

 

Because if it's bad, the clutch gear can wobble all around, and the clutch won't stay running parallel to the flywheel and flex plate. It's the only thing holding the front of the clutch gear in line with the crank. And since 4th gear is actually the back side of the clutch gear, if it's busy wobbling, it's impossible for the synchro to work right, which makes it particularly hard to get into 4th.

"The simplest explanation that fits all the facts is usually the right one".
— Occam, ancient Greek wise man, from days even before automatic transmissions