I have just got my JDM '92 Type-R FD up and running after rebuilding the motor.

When I went to drive it the clutch pedal just went straight to the deck, I then lifted it by hand and pushed it again and it firmed up, carried on pushing it and got a terrible grinding noise and vibration through the pedal.

So I jacked the car up and had the wife push the pedal whilst I looked through the lower service hole, and the fork was traveling right back into the pressure plate cover. The fork isn't bent or broken. Looking through the hole in the side of the pressure plate cover I can see that the pressure plate isn't engaging against the clutch plates, the clutch is stuck 'open', which means the diaphragm is pushing against the fork, so when the clutch pedal is released the fork is only about 1/3" from the clutch cover. It's because of that when I push the clutch pedal it pushes the fork into the cover.

Why is the pressure plate stuck like that, and can it be fixed without pulling the tranny?

 

are you sure you have a pull type clutch in your car?

 

Yes it's a pull type, here's a pic of one:



It was fine before I pulled the motor.

 

bleed the clutch system?

 

If you see the throwout bearing moving as the clutch is pressed, but nothing else is moving; then most likely the wedge colllar is either not attached properly or damaged.

 

The throwout bearing moves and the diaphragm moves slightly, untill the movement is stopped by the fork hitting the pressure cover.

 

Download one of the videos from this page:

http://www.zeroglabs.com/rx7/pullclutch.htm

It will give you an idea how the clutch works.

 

I've watched that video before, but thanks anyway. The problem is that for some reason the clutch is stuck in the pulled position.

 

Which means most likely the throwout bearing isn't locked into the pressure plate. Regardless, you are going to have pull the transmission to take a look.

 

That's next weekend gone then