Blaise
Blaise Reader
7/28/17 3:28 p.m.

UGHGHGHGHGHGH.

So a few months back I replaced the clutch in my '92 1.6 NA with a standard LUK clutch and flywheel. Stock drivetrain other than the '99 Torsen swap.

Two days out from a track weekend, it quit shifting entirely out of nowhere. I replaced both the master and slave cylinder with no help. Then I pulled the clutch fork boot and saw parts floating around...

I couldn't source a new TO bearing in time so I slapped in a used OE one. Good to go, no more problems.

Now, a few days ago I did a track day and after 3 full sessions of no problems, I started the car and couldn't get it into gear. Shut it off, put it in gear with clutch in, and it started like it was in gear.

Basically, the clutch won't full disengage with the pedal. Total bizarre thing... out of nowhere.

Getting home was a challenge. Stop at every light, kill the engine, put it back in 1st, start it in gear... then rev match whole way up. At highway speeds with clutch pedal in revs do not drop. However, if you gassed it too the revs would go up.

I checked the clutch fork and everything is moving as it should. TO bearing is on the fork and looks fine. Bled the system again to be sure with no change. Oddly enough there was crud on the bottom of the clutch master despite it being new. I cleaned that.

Really running out of ideas here. I can drop the trans but I don't see what else could be wrong.

Keith Tanner
Keith Tanner MegaDork
7/28/17 3:41 p.m.

If the arm on the clutch fork is moving about 3/4", then the answer is inside the bellhousing. I'm going to say broken spring, but it should become fairly obvious.

bentwrench
bentwrench Dork
7/29/17 3:43 p.m.

Maybe a piece of the old TO bearing has snuck in there.

Blaise
Blaise Reader
7/31/17 8:07 a.m.

Alright, I was outta town this weekend but I have a new theory: Failed (seized) Pilot bearing. Having 2 failed bearings in the same kit within a few months is HUGELY annoying but would explain the partial-engagement while the clutch fork moves. Time to pull the trans and check...

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