Hi I just swapped an automatic transmission for a manual in my 1982 GSL (not SE, just a 12a). I put in a resurfaced flywheel, a brand new clutch disc, pressure plate, throw-out bearing, and pilot bearing. the clutch fork seemed perfectly fine on the transmission i pulled from another 82. I bought a new slave cylinder, rebuilt a used master cylinder and I'm using hard and soft line i pulled from another 82 for the hydraulic system. here's the problem... after it had been running strong for about 1000 miles, as i was coming to a stop light to try and slow my car down, i pressed in the clutch pedal and nothing happened. The rpm's didn't drop a bit and as i put the brake in, the whole car started jerking, meaning the clutch was still engaged. i was able to get it out of gear and coast into a parking lot. when I called my friend for assistance, we took a look and it appears that there is no problem with the hydraulic system. The reservoir is full, there were no leaks in the hoses or cylinders and the slave cylinder is pressing against the clutch fork to make a squeaking sound as the fork moves. The pedal seems to feel the same as it did when the car was running well. From what else i've been able to gather from other online forums, people say that there are two or three possible problems causing this... 1: There is air in the clutch line so the slave isn't pushing far enough (but as i mentioned the pedal still feels normal), 2: The clutch disc and pressure plate are old and too worn up to move or work properly (but as i mentioned both these are brand new), or 3: The clutch fork came loose from the throw-out bearing and therefore won't release the clutch (but i should add the car will start fine with now problems or weird sounds while it's in neutral). So BIG problem here. just wondering if anyones encountered something similar? I don't want to pull the transmission again unless i absolutely have to.



Thanks,

Max

well if its fine in neutral it is a clutch problem, so thats good.



you've got the possibilities outlined pretty well. i would actually try and move the clutch fork by hand, if you can you're either really strong or something isnt right.



its possible that the master isnt working, it can just not move the slave enough, any leakage is actually inside the car.

Well I just got my wisdoms pulled out after I removed the starter to try and peek up in there. but if I'm feeling up to it I'll go check the cylinders tomorrow. but like i said, the reservoir in the master seems pretty full so would leakage be slow? and since it runs fine in neutral why would it be internal? i just really dont want to drop that tranny out again... it almost seems as if the reservoir is filling up more... OK i just went out and checked my car. i cant budge the clutch fork but there is no liquid coming out of the master...

I remember when We put the clutch in we hammered the pilot bearing into the flywheel but there was another piece. my buddy said that was for a different application cause it didn't look like it fit anywhere. but after reading up on it, it turns out that's the pilot bearing seal... could my problem be the result of a failing pilot bearing? how does the seal fit in/where does it go?

Well I just dropped the transmission and sure enough, sitting on the input shaft is the pilot bearing, completely seized to it. I had to get a chisel and cut it in half. Guess WD-40 doesn't quite cut it for grease... So I just took the whole clutch kit back to schuck's and they were willing to uphold the warranty so I'll be getting a new kit soon. Bad news is while I was examining the clutch fork and pivot ball, the old clips on the fork were so rusty they snapped off. know where I could get a new one? dealer?

Dude! at this point your best bet is hitting the dealer up for one of those clips unless you manage to find one in really good condition. Otherwise you can always get the shole fork and clip assembly from mazdatrix for about $24.00

pilot bearing first then the seal. blead the system real good.

Well I got a clutch fork from a local junk yard, put the car back together again with a new clutch and now for some reason it starts shaking really violently in second and third... but while accelerating in first its fine, also when I put the clutch in and rev up the engine no vibration happens so I don't think its engine related... drive line?