OK, I'm stymied...just finished install on all new flywheel, pressure plate, disc, throwout bearing and cable in the CRX (stock '86 DX).
It's all buttoned back up and the clutch WONT DISENGAGE even with all the freeplay removed from the cable at the actuating lever. I know that:
- the disc is installed flat side facing the flywheel
- Pressure plate installed correctly and according to specs in the FSM
- release lever, spring and throwout bearing were greased and working correct and smoothly just prior to reattachment of transmission
- transmission lined right up and slid onto locating dowels and tight to engine on the first try (a definite first for me!)
- I verified as best I can that the parts purchased/used ARE correct for the application
- I have a sometimes sound similar to a spline that is not engaged fully but I verified that both cv axles are completely seated in the differential and both wheels rotate smoothly while running in 1st gear (on jackstands)
- Upon removal and inspection, the pedal assembly is completely intact with no bends, broken metal or welds. actually looks amazing for 200k+ mileage...but I'm going to reinforce it anyway while it's out!
The whole shebang is coming back apart to try and locate the problem. I welcome any thoughts anyone might be able to offer on this so, thanks in advance!
So...I tore it apart and found that,very obviously, the clutch disc springs are rubbing on the back side of the pressure plate spring fingers, thus accounting for the noise heard! There are no apparent problems with the clutch fork,return spring or actuating lever. Everything slides smoothly and I verified that the new release bearing is the same in all ways as the old one. The clutch disc splines match the input shaft splines exactly and the kit it is from (a "LUK" part number 08_005 from Rockauto) is listed as correct for the 1G CRX application on the LUK website. I'm at a loss as to how to rectify this problem...anyone?
Picture of the new pressure plate upon removal:
http://i260.photobuc...-15-13_1029.jpg
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Edited by GeezRX, 15 June 2013 - 11:36 AM.