Clutch conundrum

[ESI-RStarion]

So I was coming up to a light about 2 weeks ago downshifted and my clutch went out, my brother had a spare clutch kit from his first tercel that he let me use, brand new pressure plate, clutch disk, release bearing and pilot bearing. I installed it and the clutch wouldn't disengage. So I took it apart inspected my work and reinstalled it. The clutch still won't disengage keeping me from putting it in gear while the engine is running but when i use a ratchet strap to pull the release lever towards the front of the car the clutch will disengage and allow me to put it into gear with the engine running. Anyone know what could be the problem? I have a feeling my answer lies in the odd self adjusting clutch pedal. Thanks for the help in advance, Andrew.

[keith]

You put the clutch plate in wrong side forward. The plate is asymmetrical, one side is marked to go towards the flywheel. Or, you have the wrong clutch assembly, there were two and the change came mid 86 model year.

[ESI-RStarion]

Clutch disk is in the correct direction, But it might be the incorrect clutch kit.

[Petros]

IF you can get it to relase by moving the lever on the bellhousing it sounds like something is not allowing the clutch cable full travel. I doubt there is an issue with the clutch. You might check your clutch cable for too much stretch, and the auto aduster if it is reset for the new clutch, and working properly.

Check the adjuster (at the top of the clutch pedel assembly) to see that it is working properly and that it is reset. Release it by hand and pump it back into postion. The new thicker clutch will cause the throw-out bearing to engage in a different location than the old clutch, which means it has to be reset so it self adjusts to the new position. The design only allows it to tighten as the plate wears, but not to back off to accomodate a new thicker clutch plate. You have to release it by hand. If that does not work your clutch cable may be stretched too far to for the adjuster accomodate the new clutch thichkness.

When ever I have had to remove the clutch cable I relase the auto adjuster to give me more slack on the cable to remove it easier, so it also resets itself when I re-engage it anyway.

[keith]

The self adjuster adjusts everytime the clutch is used, there is no reset, but the mechanism can get stuck. A little wd40 can take care of that.

[Typrus]

Mine didn't reset when the new clutch went in. Resets for wear but not what is essentially buildup (a thicker friction surface). At least mine worked that way. And believe me, its silicone-lubed to the max. I need a new clutch cable.. Stupid thing binds and pops... So freaking annoying...

[keith]

Mine reset, but then when the first clutch was replaced, so was the cable. There is nothing in the FSM about resetting it.

[ESI-RStarion]

Well kinda jimmy rigged it back together, removed the clutch pedal hieght adjustment screw to give it a few more notches of movement on the rlease sector and placed 4 washers inbetween the cable and the firewall on the engine side. Works for now but will do it correctly next day off. Which happens to be the day after payday. But for now, it works!

[xirdneh]

[. Anyone know what could be the problem? I have a feeling my answer lies in the odd self adjusting clutch pedal. Thanks for the help in advance, Andrew.[/quote]

Did you replace the clutch cable? If you did i wonder if its the right length.
The parts store gave me the wrong cable once. Not sure if there are different cables for these '83-'88 tercels or he gave me a cable for a corolla or something.

[ESI-RStarion]

Well its the clutch cable that was in the car when I bought it. But that no longer matters because I think my tranny is thrashed, went for a little road test And on the way back, about 30 miles on the new clutch first, second, fourth and fifth rattle, and third pops out of gear. Sigh.