Wierd clutch disengagement problem- Need help ASAP!
 

I just got my car running and everything, but I cant get the clutch to disengage. Its a used OS giken twin-plate. When I first started to move it, the clutch would not disengage, so I adjusted the clutch pedal out a bunch, and I got it to disengage and was able to shift into gears while the car was running. I moved it about 15 ft. The next day I unloaded it off a dolly and drove it about 100 ft, it wouldnt go into reverse while the car was running, but would go into first. About 3 hours later, tried to go take it for a spin, but couldnt get the clutch to disengage at all. Adjusted the pedal all the way out at this point, but didnt help. I even tried putting a washer between the slave cylinder pinion thingy and the throwout bearing fork in an attempt to get more travel, but still didnt do anything.

Ive checked everything short of pulling the tranny, there are no leaks in the master or slave cylinders, clutch was bled several times(didnt change anything), slave cylinder seems to be operating normally, and I checked the clutch from the inspection panel on the bottom of the tranny, the plates move about 1/32" when the clutch pedal is engaged. I noticed a noise that sounds like the throwout bearing might be going out, but its a brand new unit from mazdatrix.

Can anyone give me some ideas?

Have you checked the rubber boot on the slave cylinder for traces of fluid? I'm assuming the level of fluid stays the same?

Yes, Ive checked everywhere for fluid, no leaks whatsoever. Clutch pedal feels normal.

I just got done rebuilding the slave cylinder anyway, so Ill see if that does anything to help.

Only other thing I could think of is the clutch fork is bent, or it's the wrong throw-out bearing in that case.

Honestly sounds like a cylinder problem... master or slave, doesn't have to be showing signs of leaking for it to BE leaking. The seal inside can go and it won't do anything, fluid just pushes around the seal.

Anyway, if it's not that then the clutch fork being broken or bent is likely...

--Gary

sounds like you broke the "button" off inside the bellhousing. its the fulcrom point for the clutch fork. same thing happened to me. no leaks, pressure fine etc.. but no engagement whatsoever or very very little if /when it did,.