Just put a T5 manual transmission in my '84 Trans Am. When the clutch is pressed to the floor it won't go into gear. Works fine when pressed ~75%, but then I put it to the floor and the engine stalls. Anyone know what the problem could be, and how to fix it without screwing a block of wood to the floor? Thanks

 

Hydraulic or mechanical linkage?.
linkage needs adjustment if mechanical

 

It's hydraulic linkage, the whole system is stock straight out of an '88 TA with new clutch, pressure plate, flywheel and slave cylinder. It is supposed to self adjust.

 

The clutch fork tines and spring clip go in the same groove in the throwout bearing. If the clip is put behind it, your description is exactly what will happen.

 

Thanks jmd. I was aware of the tine issue when I installed the TOB, was conscious to do it correctly but will check. Also saw a thread about the flywheel thickness and will look into that as well and report back.

 

So this is what I've found out about why the clutch works at 75% and not at complete depression:


1) The throwout bearing (TOB) is installed correctly, looked in thru the fork boot and saw the back of the TOB with no tines behind it.


2) The fork boot is tough to reinstall.


3) I get proper travel from the slave cylinder, about .57".


4) According to gmpartswiki the hydraulic system, fork and pedal assemblies are the same for '84 & '88.


5) My '84 has a 2 piece RMS and the '88 donor has a one piece so the crank, flywheel, clutch plate, pressure plate and TOB are all different part numbers.


6) If I put a block of wood on the floor the clutch pedal won't trip the clutch safety switch and the car won't start.


But, everything fits! Head pressure pushes on the slave cylinder, adjusting it until the TOB is in contact with the pressure plate. Pressing the clutch pedal pushes enough fluid to move the slave .57" min. The TOB displacement is the same for '84 & '88 so there should be no problem.


So... I need to remove the trans and see what is causing the problem.

 

I have not had to use one. But, a shim between flywheel and crank is a common way to accomodate the thinner thickness of a machined flywheel. A taller ballstud would possibly help too.Yes, I saw your flywheel is new. That doesn't mean it's identical to stock. And you can't rule the clutch out, either. Did you bleed the hydraulics?

 

Thanks again JMD. I took the tranny out and had an experienced friend over to check this out. We measured ~.72" travel in the clutch slave. I'm pretty sure it's bled, if it wasn't we wouldn't see that much travel correct?

Found out it's not head pressure but a spring that pushes the slave piston until the TOB contacts the pressure plate. My friend was surprised that the TOB is ALWAYS in contact with the pressure plate. Said there should be a gap, but he is most familiar with second gen trannies. Is the TOB always supposed to be in contact or am I missing something?


We didn't see anything obvious so I will reassemble and pay attention to all details of the button up. Maybe the fork was binding somewhere.

 

I reassembled the trans and everything worked fine. No telling what the problem was.