Quote:
Originally Posted by JB3
This is the first time ive tried to match non stock hydraulic components like this, so if anyone has any advice or experience, id welcome their input!
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I will offer my experience with my neighbors Ford Escort. He hired me to put in a new clutch because it was worn so bad, the engine would rev in all gears higher than 4th. I replaced everything with new parts (flywheel, pressure plate, disc, pilot bearing) sourced from Amazon (my neighbor likes Amazon). After removing and reinstalling the trans THREE times to check for different potential problems, I still could not get the clutch to disengage without grinding the gears. We even replaced the entire hydraulic system with new parts, and still the same problem. The experts (including me at first) suggested it had to be the pilot bearing too tight to the input shaft. After the first time R&Ring the trans, the bearing was checked and was found to be fine. The second time, the clutch and pressure plate were replaced with new (again). The third time we double checked everything and still could not find the problem. This all happened about three months ago, and the car still sits with no idea as to how to fix it. However, I suspect you may be having a similar problem with yours. The thing I did not check was how tight the disc fit on the splines of the input shaft before installing the clutch. The alignment tool fit perfectly in the clutch, but thinking back, it was a little hard to pull the trans tight to the engine for the last one inch or so. I am half tempted to hole saw a hole in the bottom of the bell housing to see if the disc is freely moving on the input shaft while someone depresses the clutch. You may have the same problem. You could have a problem with your pilot shaft bearing as well, as yours is not a stock application. I would first try (with help and the rear on stands with the parking brake on) to test if the clutch is or is not disengaging manually (actuating the clutch fork with a lever), thereby eliminating the hydraulic system from the test. This will tell you if mechanically the clutch is working properly, and you can rule out or look to an input shaft problem (splines or input shaft bearing/bushing too tight).
This test was performed on the Escort, as we thought the fork might have been bent, causing less than adequate disengagement....Rich