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General Information => Troubleshooting => Topic started by: BP10000 on September 11, 2009, 07:35:32 pm
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So I got my replacement engine all sorted out and everything's working great, except shifting is a lot harder than I remember.
The problem I'm having is that the clutch won't fully disengage, making it very hard (and noisy) to get into reverse at a standstill. The release arm on the trans moves easily up to horizontal before meeting resistance. The cable seems to be adjusting just fine.
On reflection, I seem to recall a small silver metal disc, maybe 5mm diameter and 2mm thick, lying on the floor in my garage. I thought it was a punchout from something. Could this be part of the clutch release mechanism? Please tell me i can pop it back in from the outboard end of the trans...
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You can't really see it in this picture but did it look similar to the small disk in the center?
http://image.autopartsonlinecanada.com/live/I2036324528SAC.JPG
I hope you say no...
The disk you found, did it have an impression in one side of it?
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Here's how all the parts fit together:
(http://i197.photobucket.com/albums/aa85/vwaldon/clutch.jpg)
Part 14 is the part Tyler is referring to.... although it's a bit bigger than 5mm.
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ahh, good graphic!
there was definitely a disc of some sort still in the dimple in the center of the release plate. It had a slightly burnished area where the rod pushes. The disc I saw, and my memory could be playing tricks on me, looked like it was made of aluminum and was slightly convex like it had been punched out of a sheet. I didn't even pick it up, so it's really only half a glance I'm going on. I wonder if someone stuck it in the release bearing as a shim at some point. Maybe it stuck to the end of the rod when I pulled it out and then fell off.
How much total travel does the rod make to release the clutch? what would a 2mm shim work out to in lever arm travel?