Hi all,

As some of you may be aware I'm in the process of doing a manual conversion.

I've fitted up the gearbox and I'm having issues getting the clutch fork to pull back and the throwout bearing to engage. The fork keeps returning towards the engine and therefore my slave cyclinder can do nothing. I can physically move the fork, and the bearing touches the pressure plate but when I let go the fork pulls back to towards the gearbox. From my understanding and looking at the hydraulic lines and the setup, the bearing & clutch fork should naturally pull towards the gearbox/passenger side, and then the slave cyclinder (when you push the clutch) pushes the fork towards the engine and the clutch moves to allow a gear change.

So why isn't this occurring? As a result my clutch pedal is just pushing to the floor and not retracting.

I appreciate any and every help.

Thanks heaps everyone!

You have to snap the throwout bearing into the clutch face, you have to lean hard on it in the "opposite" direction (pull towards the passenger side) to click it in.

If that's not working I am guessing your clutch plate wave spring is damaged.


I have a little video about this here, it was designed to explain how to REMOVE the thrust bearing but might help you understand in general.


http://www.youtube.com/watch?v=SF4hO-G3YxA

In short, I would say you have damaged the spring clip when you installed the gear box, I have seen this done several times by people who have not done these before.

If the fork will not snap into the bearing then you have damaged something. Remove the box and have a good look

Thanks heaps for the response and help guys!

Lathiat that video is great. Book marked for the next "Why won't my manual gearbox come off" thread :)

Mal that was our nitial suspicion's. It seemed the bearing wasn't engaging but after a good inspection, we discovered that it actually is. We actually removed and re-clipped on the bearing about two times just to make sure it is actually engaged and it was.

We did however discover what we believe to be the real problem: we did not replace the throwout bearing. --> Does the 240mm 380 HD clutch kit have a different bearing to the Factory-fitted 3L 225mm Magna standard clutches? If so then this may be our problem. We omitted fitting the new bearing that came with the clutch kit instead just leaving the one already in the gearbox which would be the 3L stock factory fitted one.

After much deliberation we discovered that the clutch is not disengaging enough. The bearing does not seem to pull the clutch back enough when the car is in neutral. We fully bleed out all the air in the lines and rebuilt the slave cylinder, to find that the clutch fork was being pushed as far as it can go toward the engine and the clutch was still engaged (evident by the wheels spinning fast after we put the car in gear, took it out of gear and pulled the clutch pedal back).

Otherwise to anyone who has fitted a 380 240mm Exedy HD clutch kit - Is the 380 clutch fork different to the 3L clutch forks and does the 3L/3.5L manual clutch forks need to be replaced with the 380 ones??

Appreciate the help fols. I might change the name of this thread.

So for clarity.. what gearbox, clutch kit and motor do you have?

So for clarity.. what gearbox, clutch kit and motor do you have?

Gearbox: 3L 5sp from a TE
Clutch Kit: 380 240mm Heavy Duty Exedy kit - flywheel had a step machined into it.
Motor: 3.5L 6G74

:)

For starters, why the hell did you not replace the bearing, the kit you have would have come with a new one

NO the bearings are not different

What flywheel did you use, if you used the Manga one I have already told you that it will not work.

Either way, you have stuffed something up, the basic points have been covered, there is not much else that can be covered on a forum without looking at the job being done, thus why it is sometimes better to just for out the cash and get it done professionally......

Admittedly it was a bad decision not to replace the bearing. We were just running out of time and weren't too sure we'd be able to refit the spring. It seems to be under a lot of pressure. So we opted to leave the old bearing in there. We will be taking off the gearbox again and replacing it with the one that came in the kit. But if the bearings are not different then must not be the issue.

We did actually use the original 3L magna flywheel but I had a step machined into it. I was following Neo's advice in my thread when I asked about clutch options for my setup. See Here (http://www.aussiemagna.com/forums/showthread.php?t=93528&p=1468303&viewfull=1#post1468303). Do you think this is the problem? Would this explain why the clutch is not disengaging properly.

Should I have got a 380 flywheel? If so - do you have any in stock? I'll try and come by your workshop to buy one from you :)

The flywheel step is nothing to do with the reason to use the 380 flywheel. You do the step when you get the MAGNA 240mm clutch kit, NOT the 380 one.....

The flywheel step is nothing to do with the reason to use the 380 flywheel. You do the step when you get the MAGNA 240mm clutch kit, NOT the 380 one.....

Thanks for clarifying! That makes sense now.

I should have bought the 240mm Magna clutch kit. (Exedy Part Number: MBK-7223)

I bought the 380 version - MBK-7702. I'm told by the workshop that this is actually a heavy duty version as there was no option for a standard oem replacement kit.

Is there any advantage of getting the 380 clutch over the 240mm magna one? I'm thinking of either buying the magna clutch kit or getting the 380 flywheel. Is the magna flywheel too big for the 380 240mm clutch kit?

Thanks again everyone for the help! Really do appreciate it :)

Thanks for clarifying! That makes sense now.

I should have bought the 240mm Magna clutch kit. (Exedy Part Number: MBK-7223)

I bought the 380 version - MBK-7702. I'm told by the workshop that this is actually a heavy duty version as there was no option for a standard oem replacement kit.

Is there any advantage of getting the 380 clutch over the 240mm magna one? I'm thinking of either buying the magna clutch kit or getting the 380 flywheel. Is the magna flywheel too big for the 380 240mm clutch kit?

Thanks again everyone for the help! Really do appreciate it :)

Dont know where this "workshop" is but they are wrong, ther 380 is a std duty not a heavy, heavy are not avail. There are a few benefits with the 380 set up, you would really need to understand how these work to get the idea of why I use them

You have the 380 clutch now so may as well get the flywheel, can not return a used clutch anyway

Dont know where this "workshop" is but they are wrong, ther 380 is a std duty not a heavy, heavy are not avail. There are a few benefits with the 380 set up, you would really need to understand how these work to get the idea of why I use them

You have the 380 clutch now so may as well get the flywheel, can not return a used clutch anyway

That's a shame. I was hoping for a heavy duty kit so the clutch doesn't wear out that fast and it'll last a good few years. Too late now though - the standard 380 one will have to do. I have a decent understanding of how a clutch works - are you able to briefly explain the benefits 380 clutch & flywheel? I figure it might be useful for others in the future as well?

Do you think the issue would be resolved with a 380 flywheel? If the magna one is too big then I can understand why the clutch isn't disengaging properly and hence why the wheels are spinning when they shouldn't.

Anyway I'll organise to try and get to your workshop this week and pick up a 380 flywheel.

Thanks heaps for the help!