Clutch replacement problem

Tiny
DON KLEPPINGER
  • MEMBER
  • 2004 CHEVROLET CAVALIER
  • 2.2L
  • 6 CYL
  • 2WD
  • MANUAL
  • 140,000 MILES
I replaced my manual transmission and replaced clutch while I was at it. The clutch will not engage. It is like the clutch pedal is always depressed. I can put it into gear with the engine running and the wheels do not turn. Although I can turn a wheel and will turn half a turn on it's own so it is barely touching. Clutch came with a new slave cylinder that I installed and bled, but it can't really be the slave cylinder because the symptom would be opposite, i.E. Cannot disengage instead of engage. The new clutch looked exactly like the old one. I used the centering tool to install it. Before I have to drop the transmission again does anyone know what I might have done wrong? The old clutch was working fine before replacing it. I also took off the flywheel and replaced the rear seal.
Wednesday, March 20th, 2019 AT 1:35 PM

7 Replies

Tiny
JOETECHPRO
  • MECHANIC
  • 705 POSTS
Hey DON KLEPPINGER,

To confirm the clutch currently pedal feels normal?

For the clutch to be stuck disengaged as you said the only thing that comes to mind is the slave is holding on.

You could try removing the slave from the transmission and then seeing if it will still go into gear.
It should not go into all gears with the engine running.

That would rule out the slave.

Then you would be looking at removing the transmission to recheck installation I cannot see any other way unfortunately.

Regards, Joe
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Wednesday, March 20th, 2019 AT 2:06 PM
Tiny
DON KLEPPINGER
  • MEMBER
  • 4 POSTS
The clutch pedal presses down a lot easier than it used to but does push back out and got slightly stiffer after bleeding it but still pushes in what I think is way too easy. The slave cylinder is on the inside of the transmission so I can't remove it without removing the transmission. I can only disconnect the line. I'm wondering if I put the clutch disk pad in backwards but I don't think it would have even fit that way.
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Wednesday, March 20th, 2019 AT 2:29 PM
Tiny
JOETECHPRO
  • MECHANIC
  • 705 POSTS
Hey DON KLEPPINGER,

It is definitely possible with some clutches to fit friction plate the wrong way round and it will cause you issues. The friction plate usually has gearbox side or similar written on it to make sure you fit it the right way round. You will not be the first person to have made this mistake.

The pedal does not return after you push it down?

If so there must be something already compressing the pressure plate. Or it is not bled properly but as you described the clutch would then be permanently engaged.

Did you have difficulty getting the transmission to seat?
Have you checked the transmission is seated flush to the engine?

Regards, Joe
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Wednesday, March 20th, 2019 AT 3:27 PM
Tiny
DON KLEPPINGER
  • MEMBER
  • 4 POSTS
The pedal does return when I release it. It just doesn't take much force to push it down. It didn't take too much to get the transmission to seat once I got the splines of the shaft lined up. It is bolted to the engine solid and torqued down. No gap. I will drop the transmission again this weekend. It's a pain but it should go faster the second time. :-)
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Wednesday, March 20th, 2019 AT 7:03 PM
Tiny
JOETECHPRO
  • MECHANIC
  • 705 POSTS
Hey DON KLEPPINGER,

Sorry again, but I cannot see any other way of getting to the cause of this issue apart from removing the transmission to inspect.

Please update us on you progress.

Best of luck with dropping the transmission, it is always easier the second time around.

Regards, Joe
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Thursday, March 21st, 2019 AT 8:37 AM
Tiny
DON KLEPPINGER
  • MEMBER
  • 4 POSTS
I feel real stupid. The problem was because the clutch wasn't put in the correct position. There are 3 recesses on the flywheel that must be matched with the three spring pins on the clutch. It was turned so the pins didn't match the recesses so when I tightened it down the clutch did not seat all the way into the flywheel. Actually the clutch fingers straighten out when you do that like the clutch is already depressed. If I had spun the centering tool I would have noticed that the clutch plate spun freely. First time doing a clutch. Now I know better.
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Monday, March 25th, 2019 AT 1:24 PM
Tiny
JOETECHPRO
  • MECHANIC
  • 705 POSTS
Hey DON KLEPPINGER,

Like I said before you will not be the first person nor the the last to do this.

People make mistakes, even professionals.

Glad you got it figured out. Take it as a learning experience, you'll never do it again. You can also now probably get that transmission in and out with you eyes closed. : )

All the best.

Regards, Joe
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Monday, March 25th, 2019 AT 5:04 PM

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