quote Originally posted by McCool: 1" of movement on both the master and slave...

quote Originally posted by McCool: I talked to Rodney, He said that the travel I am getting on the master and slave cylinder is about right, and if the clutch plate is still making contact at this point, the problem lies somewhere after the slave.

Rodney knows more than I do. My experience with Isuzu 5-spds though is that "about right" is not good enough. Over an inch of slave travel is required for proper clutch disengagement. However, I've found that my Getrag 5-spd is much more forgiving. I admit to having very limited experience with Muncie 4-spds. With your maximum slave travel limited to 1", it probably isn't acceptable to have any margin of error in any component beyond the slave. Maybe the fork is bent a bit. That sucks though.

[This message has been edited by Patrick (edited 06-25-2019).]

Just an update for when this thread gets archived.

After following the advice given in this thread, I was unable to fix the problem. I took the car to a mechanic, they took a look at all the work I did, said it was good and agreed that the problem was in the clutch housing. They dropped the engine and sure enough, one of the torsion springs from the clutch plate had broke loose and wedged itself in such a way that the plate could not fully disengage.

I am going to update my first post to save the next guy some trouble, feel free to critique and mention some points I should consider adding.

Thanks for all your help guys.

quote Originally posted by McCool: ...one of the torsion springs from the clutch plate had broke loose and wedged itself in such a way that the plate could not fully disengage.

Are you referring to one of those little coil springs in the clutch disc?



Yeah, that would certainly be enough to ruin your shifting... and your day. Glad you were at least able to determine the issue. Thanks for letting us know.

quote Originally posted by Patrick: Are you referring to one of those little coil springs in the clutch disc?

Yup, that was the culprit.