So I just finished rebuilding my 2.8 V6 engine and re-installed it in the car with a new clutch, throwout bearing and re-surfaced flywheel. And upon trying to put it in gear, I found that the clutch will not release. There is a good inch of throw in the slave cylinder, so no problems with the hydraulics. I inspected inside the bellhousing with an inspection camera and can see the throwout bearing pressing against the diaphram as it should. So what could be keeping it from releasing??
------------------ My Fiero: 1986 Pontiac Fiero GT, V6, 4-speed manual
tuggajb and Gall are correct. The center hub of the clutch plate protrudes more on one side of the disk than the other. The disk should have been marked "Flywheel Side". Do you get any noise or pedal pulsations when trying to disengage? A sure sign of being installed backwards.
[This message has been edited by fierofool (edited 10-14-2016).]
No odd pulsations but it does make a scraping/rubbing sound when starting the engine in gear and clutch pedal pushed, as the clutch disc is moving slightly with a lot of friction. Given that I couldn't find any problems with the hydraulics/slave cylinder throw, this must be the only thing that could be wrong. Looks like the clutch is coming out and getting reversed around tomorrow...
------------------ My Fiero: 1986 Pontiac Fiero GT, V6, 4-speed manual
I would rule out a master cylinder leak first. Try pumping the clutch pedal. A lot. Normally pedal travel will suffer if the master is failing, but it's one that has caught me totally off guard. I have issues with mine in my 87GT that appeared immediately overnight, went away for a month, then resurfaced. Ya never know, worth looking at.
This issue may be from the PP being manufactored wrong. I ran into this issue on a swap months back and so far have talked to 5 others that did clutch swaps with the same ene results. The PPs rhat come with clutch sets now are not the old sawblade design but more of a design like the 4 speed PP has always been. So far each clutch set used has been a different maker including SPEC.
Why did you have to get the different throwout bearing? The clutch set should have come with the proper bearing. I'm assuming they must have given you an assembly for an 86 V6 5-speed?
Even though the 86 V6 5-speed was a late-year introduction and relatively few were produced compared to 4-speeds, most parts suppliers don't show the 4-speed in their listings. Because the 86 model year was available with all 3 manual transmission versions, it's best to order the 4-speed V6 assembly for an 85 and if ordering for either of the 5-speeds, order it for the 87. In those two years, the proper assembly is defined by the engine and most parts houses show the proper assembly.
[This message has been edited by fierofool (edited 10-17-2016).]
As far as the throwout bearing, I just know that the original one in my 4-speed was completely different from the one that came in the kit. The Napa I ordered from apparently only included the 5-speed throwout bearings in their kit, so I had to order the throwout bearing separately. From all info I could find, the pressure plate and disc are the same between 4 and 5 speeds...
------------------ My Fiero: 1986 Pontiac Fiero GT, V6, 4-speed manual
I took out the clutch today and sure enough, the little "flywheel side" engraving on the disc was facing the transmission. And there were some scuffs on the torque springs. Flipped it back, and hopefully that does it!
