5K / K50 Clutch Problems

[KaneKE70]

Hey guys, I have a ke55 coupe, 79 i think - I've taken out the old auto/3k, and bought a 5k/k50 from chief on this website. The engine has a new clutch kit bolted to the flywheel.

After putting the gearbox and engine into my car i found that the clutch fork was very loose. I thought it may have been normal as there was no return spring on the clutch lever and no cable at that point. After hooking up the clutch cable and return spring i still had the same problem, and the pedal was going straight to the floor without any decent resistance.

So i pulled the gearbox back out, and saw that the clutch fork was very loose, and that the spring had come off that holds it on to the actual gearbox itself.

So i crimped the spring over the little ball/knob type thing that it gets held on to, and thought this would fix my problem. After putting the gearbox back in

i found that the pedal was still going straight to the floor. I even took the clutch cable off, to see if i could manually disengage the clutch by hand, but the clutch lever was still really easy to pull forward, all the way to the front of it's travel.

I know this has nothing to do with the clutch cable adjustment, as i have spent alot of time trying to fluff around with that. I'm thinking i may have matching problems with my gearbox/flywheel/clutch kit. Can anyone help me out here?

I'm thinking i may need to get a 4k flywheel and clutch kit? The gearbox input shaft appears to be sliding into the clutch plate perfectly, the bellhousing goes all the way in flush with the engine and bolts up fine - and when the car is put in gear, and is tried to move forward or back wards it does not move.

This is such a pain in the ass and it's doing my head in haha!

Cheers guys,

Any help would be greatly appreciated - it feels like my project had grounded to a halt because of this problem.

Thanks,

Kane

[coln72]

silly question, is the throw out bearing fitted?????

[GJM85]

I'm thinking i may have matching problems with my gearbox/flywheel/clutch kit.

 

this could very well be the problem. 5k flywheels have 200m clutch face instead of the 180mm 4k flywheel. the 5k clutch then also suits a 21 tooth input shaft and the k series gearboxes have a 19 tooth input shaft, with the exception of extremely rare k50 gearboxes which did have a 21 tooth shaft. extremely rare...

Edited December 19, 2010 by GJM85

[KaneKE70]

Yes, the throw out bearing is fitted :D

Yeah man, I'm thinking the clutch setup is wrong... but would that make the clutch lever go all the way forward, without disengaging the clutch? I was thinking that the pressure plate may be faulty somehow... but it's brand new it's really doing my head in!!

[GJM85]

Yes, the throw out bearing is fitted :D

Yeah man, I'm thinking the clutch setup is wrong... but would that make the clutch lever go all the way forward, without disengaging the clutch? I was thinking that the pressure plate may be faulty somehow... but it's brand new it's really doing my head in!!

 

Can't say i've ever experienced it but that could well be an effect duue to the clutch plate not actually being stabilized on the spline. There is however, a pin that links the throwout bearing to the clutch lever assembly. If your missing that strange looking pin your throout bearing could be free bangin also.

[coln72]

Just cause it is brand new, doesnt mean the pressure plate is ok. My old man went through 3 or 4 new pressure plates in his HZ before he cracked the shits and got one of the new ones reconditioned. All of the new ones shuddered like a bitch and when you looked at them, the fingers were either bent or cracked on the new ones (some were genuine GMH). Through the recoed one in and no issues.

[KaneKE70]

GJM85,

what is this pin you are referring to? I don't remember seeing one on the fork assembly when i pulled the box out to check things out. Is there any chance you would have a pic of the pin? Maybe this is my problem....?

Coln72, yeah man, i've seen pressure plates bugger up from brand new, however mine looks like it's in tiptop shape man.

Cheers guys, this has been a big help so far.