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Old 04-20-2014, 10:51 AM   #1
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Default Pulled trans - maybe didn't have to?

The car: '90 chassis and trans, '05 MSM engine
Relevant new parts: 949 1.8 organic + light FW, slave, 949 clutch flexi-line
Symptom: clutch will not disengage/shift into gear when running. Observed clutch fork slop fore and aft, as well as vertically.

Observations:
Bled clutch. More bleeding of clutch. Then we bled the clutch. Ultimately we did it again. There's no bubbles, Georgio.
Seemed like the PP wasn't pressing against the TOB at all, thus the massive slop in the fork. Though, there was some pedal feel, but inconsistent. The "resting" location for the fork was much further toward the back of the car as compared to this example (this one rests much more compressed than mine):



This would mean there's almost zero room for travel, but maybe it doesn't take much?

Adding to the inconsistency, pumping the pedal sometimes resulted in a loud CLICK CLICK CLICK. Slowing things down, the click was occurring after about a .5" release of the pedal. Weird.

Being this thing felt completely broken, the trans was pulled. I'm not confident the correct decision was made.

The fork spring was possibly off the pivot ball. I feel like it may have clicked back into place the first time I started to test out the motion in the ocean. Could also be me trying to justify the trans pull.

I can see through the fingers on the PP to see that "TRANS SIDE", written on clutch is facing me -- thank you 949 for that. So, that half seems assembled properly.

Came inside, exhausted. Googled my *** off. Then I found this post, which seemed to ring true (Keith at FM):

ClubRoadster.net - View Single Post - Flyin' Miata Happy Meal not Disengaging

Is the 949 setup a similar situation? More pedal travel required to hit that last bit of stroke to push the heavy PP springs in? Just needed to adjust the pedal?

Bonus question: I'm not 100% sure that the appropriate thread sealer was used on the FW bolts. But, I see no leakage. Pull it and redo?

I'm not sure. I'd like some help before I make any further silly, laborious decisions.
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Pulled trans - maybe didn't have to?-kif_0841.jpg  
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Old 04-20-2014, 02:26 PM   #2
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That problem is supposedly specific to the FM clutch. You could have a defective PP with the same problem, but I think that would make you the only one.

Have you tried adjusting the clutch pedal? I had about an inch and a half of play in the rod that connects the pedal to the master cylinder.
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Old 04-20-2014, 02:30 PM   #3
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I didn't try adjusting the pedal, which was silly now that I think of it.

The slop in the fork seemed fatal, it really didn't seem like there would be enough room for the fork to disengage the clutch before it hit the edge of the "window" into the trans
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Old 04-20-2014, 02:31 PM   #4
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I just put in a new clutch last night, before adjusting the pedal I couldn't go in gear with the car running. Adjusted the pedal and it was all good
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Old 04-21-2014, 02:55 PM   #5
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Reinstalled flywheel w/ appropriate amount of 242.
Ordered a replacement pivot and clip as cheap insurance.
Nervously optimistic for a successful reinstall.
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Old 04-21-2014, 09:41 PM   #6
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My FM clutch wouldn't disengage until I adjusted the pedal rest all the way up and then adjusted the rod length. It took a couple months for me to be able to adjust for shorter travel. My engagement points are different now, should probably readjust it again.
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Old 04-23-2014, 10:54 PM   #7
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Follow up:

Just took an unexpected call from Emilio, definitely not the hydraulics... Problem w/ the PP.
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