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Clutch Problems


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#1
85Beater

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Earlier this week my clutch got out of adjustment, had to go all the way to the floor to BARELY get it in gear. A quick read of a manual led me to the adjusting nut on the cable, problem solved.

Three days later (today)...

I'm driving up to work and the shifting goes from smooth the hard in a matter of minutes. Then I'm at a light and when I clutch to grab first I hear a light pop and the pedal goes mostly loose and I can't get into any gears. I hop out and check the cable, looks good, still about 4-5mm of free play on the release lever on the trans. So I tighten it until there is almost no free play, and I was able to turn the car off, start it with the clutch in (which was still not fully disengaged) and then rev-match my way into a wal-mart parking lot. After playing around with a couple of things, and check connections, I finally ended up adjusting the cable WAY out of spec (a good bit of tension on the release lever, no free play at all) to get the clutch to fully disengage and get it home.

As it sits now...

In my driveway, semi-driveable. With the lever adjusted to the point of tension, the clutch is grabbing and releasing where it did with about 5mm of free play two days ago. Still dont know where that pop came from, or where it is. The clutch cable is still happily connected at both ends as it should be.

I'm thinking throwout bearing? I've talked it over with a friend of mine who is also a veteran 1G owner and that was our consensus, wanted to see if anyone on here thought different/agreed. The clutch has no slippage in it and other than that one time pop, there are no abnormal noises anywhere. Other than that release lever having tension on it when there should be free play, it drives as it did last week when nothing was wrong.
1987 CRX DX - Devacced, excellent interior, runs perfect, the fun car.
Note: 1G CRX's are not durable against late model motorcycles...

1995 Integra LS Sedan - Bone stock except for Brembo rotors and upgraded pads

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#2
'85-SI

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You might check the cable bracket under the dash... where the pedal holds the end of the cable... it is known to break the tack welds and the bracket comes apart from the pedal assembly. Look up at it from the floor board and you will see what I am talking about. I had it happen to me and I just had to reweld the cable bracket to the pedal assembly.

#3
85Beater

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QUOTE ('85-SI @ Dec 4 2008, 01:43 PM) <{POST_SNAPBACK}>
You might check the cable bracket under the dash... where the pedal holds the end of the cable... it is known to break the tack welds and the bracket comes apart from the pedal assembly. Look up at it from the floor board and you will see what I am talking about. I had it happen to me and I just had to reweld the cable bracket to the pedal assembly.


Hmm... the bracket that the cable feeds through does seem to be broken as you said. There's a piece the cable actually attaches to, and another that the cable feeds through on its way to the hole in the firewall (which it doesn't seem to line up with that hole anymore). I'll see if I can get a good picture of it.

QuickEdit: Left my digital camera in my brothers truck, no pictures, but if you've seen it you should know what I'm talking about.

I remember the pedal assembly being a pain to remove on my parts car...
1987 CRX DX - Devacced, excellent interior, runs perfect, the fun car.
Note: 1G CRX's are not durable against late model motorcycles...

1995 Integra LS Sedan - Bone stock except for Brembo rotors and upgraded pads

85Beater's Vouch Thread

#4
Screech

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Never pulled one from the CRX, but on the Civic its not too bad aside from the position to get to it. hardest parts are maneuvering it around the steering and that cotter pin for the brake booster.

Screech
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84 Civic 2000S (B20Z2 2.0l, SMF)
 


#5
strudel

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Look Here for a picture. There may be more if you do a search but this is how to repair it with exuberance! JS

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#6
85Beater

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QUOTE (strudel @ Dec 4 2008, 06:07 PM) <{POST_SNAPBACK}>
Look Here for a picture. There may be more if you do a search but this is how to repair it with exuberance! JS


Lol, dont think I'll go quite that far... but that seems to be the exact piece thats broken, so thanks for the picture confirmation. I'll pull it tomorrow and see if I can't track someone down who owns a welder!
1987 CRX DX - Devacced, excellent interior, runs perfect, the fun car.
Note: 1G CRX's are not durable against late model motorcycles...

1995 Integra LS Sedan - Bone stock except for Brembo rotors and upgraded pads

85Beater's Vouch Thread

#7
'85-SI

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Pullin that pedal assembly out its only a few bolts... Unhook all the cables and it will pull out pretty easily.
You will see where it was supposed to go and just have it welded back together
Easy as pie! Haha. Have fun.

#8
85Beater

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Ok, pulled it out (easy my arse, maybe for a 4' 2" child, not for 6' 3") and it wasn't completely broken, just starting to tear the metal. I pounded it back to where it should be and took it to the shop down the road who layed a LOT more welding (in a good way) than I was expecting... it will never, ever, ever break, ever.

Long story short, glad it wasn't the throwout bearing. Chalk up another victory to the collective brain that is RPR!

It shifts a LOT better now, there was a roughness to the pedal before I never liked, now its baby smooth and quiet, I love it.

Cliff notes on the removal/install;

Tools:
ratchet
12mm deep socket
12mm regular socket
4-6" socket extension
flathead screwdriver
needle nose pliers


12mm nuts x 4 (attaching it to the brake booster through the firewall)
12mm bolt x1 (attaching it to the upper part of the dash)

The best way to get the throttle cable off is the pry with a flathead screwdriver under the white washer attached to the top of the pedal. Pry up and away from the firewall, pulling the cable up and out afterwards.

The brake lever was the easiest part, a simple cotter pin and pull the bolt out. Also remove the wiring harness leading to all the brake lights.

The end of the clutch cable hooks up and around the clutch pedal at the top. Mine was seated pretty good so if you put something between the end of the clutch cable and the firewall and pull the clutch pedal up, it should pop right out. It helps a lot to loosen the clutch cable at the bracket near the transmission to give you more cable to work with.

After you remove all the bolts, the two cables, and the brake lever, its a game of put the square peg through the round hole to get the assembly out; Just keep trying, it does come out without removing anything else.



Install is the opposite of putting it in, a no brainer there. Remember to readjust your clutch cable and your good to go.
1987 CRX DX - Devacced, excellent interior, runs perfect, the fun car.
Note: 1G CRX's are not durable against late model motorcycles...

1995 Integra LS Sedan - Bone stock except for Brembo rotors and upgraded pads

85Beater's Vouch Thread

#9
1GEN_SI86

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QUOTE (85Beater @ Dec 8 2008, 02:47 PM) <{POST_SNAPBACK}>
Ok, pulled it out (easy my arse, maybe for a 4' 2" child, not for 6' 3") and it wasn't completely broken, just starting to tear the metal. I pounded it back to where it should be and took it to the shop down the road who layed a LOT more welding (in a good way) than I was expecting... it will never, ever, ever break, ever.

Long story short, glad it wasn't the throwout bearing. Chalk up another victory to the collective brain that is RPR!

It shifts a LOT better now, there was a roughness to the pedal before I never liked, now its baby smooth and quiet, I love it.

Cliff notes on the removal/install;

Tools:
ratchet
12mm deep socket
12mm regular socket
4-6" socket extension
flathead screwdriver
needle nose pliers


12mm nuts x 4 (attaching it to the brake booster through the firewall)
12mm bolt x1 (attaching it to the upper part of the dash)

The best way to get the throttle cable off is the pry with a flathead screwdriver under the white washer attached to the top of the pedal. Pry up and away from the firewall, pulling the cable up and out afterwards.

The brake lever was the easiest part, a simple cotter pin and pull the bolt out. Also remove the wiring harness leading to all the brake lights.

The end of the clutch cable hooks up and around the clutch pedal at the top. Mine was seated pretty good so if you put something between the end of the clutch cable and the firewall and pull the clutch pedal up, it should pop right out. It helps a lot to loosen the clutch cable at the bracket near the transmission to give you more cable to work with.

After you remove all the bolts, the two cables, and the brake lever, its a game of put the square peg through the round hole to get the assembly out; Just keep trying, it does come out without removing anything else.



Install is the opposite of putting it in, a no brainer there. Remember to readjust your clutch cable and your good to go.



+1 - that is how a post should always end! nice info there, nice to hear you got it back together...

#10
'85-SI

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Yeah I'm only 5'7" so it is relatively easy... 6'3" is too tall for a crx at all... Haha! You need an SUV! smile.gif