Clutch hydraulic system

[Kracka]

I believe the way the FWD slave mounts to the tranny is different. I'm not 100% positive about that, so don't quote me on that.

I am pretty sure you are right b/c I remember that being my problem. Just buy a new AWD slave cylinder to keep thing quick and easy; I highly doubt the small differences in size will make a difference.

[iceminion]

Turns out you guys were correct!

The only way to use the FWD slave cylinder is to run new metal brake line....which I am not willing to do now.

Here is a picture of the FWD(yellow cap) vs. AWD (blue cap)

[Andrew7dg]

This may sound like the dumbest question but this is what happened when I put my ACT2600 in, engagement point was close to the ground of the car, but it was an easy fix...

you did adjust the rod connecting the petal to the master cylinder right?..

From what I understand people buy the extended rod so that they don't have to adjust the clutch or it will adjust the clutch for them, however it is easy to adjust it right at the petal.

Anyway I am just starting with the most simplest things first.
This worked for my GSX anyway
I say stay with the stock vr4 system because that system should work. I have never seen anything that said swapping master cylinders and slave cylinders to make clutches work...

[dragonforce]

Most likely you have worn out pedal assembly. To check, first you can depress the clutch pedal all way down. Second release the pedal. Third try pulling the pedal up with your hand or foot. Your pedal is worn out if you can feel any movement.
You can fix this by adjusting the rod (temp fix). replace the whole pedal assembly. The best way to fix is to weld the end of pedal rod. I've done few of these.

[iceminion]

Thank you Andrew for your suggestion, and yes, it is adjusted all the way out, anymore and the u-shaped nut would fall off the end.

dragonforce - on post #1 and #4 I said that I checked for play, but thank you for the write-up...I did it a different way, I got upside down, stuck my head where your toes go, and wiggled the pedal with one hand and looked at the other side of the assembly with a flashlight, about .5mm of play due to the peg diameter vs. hole diameter.

[JET]

Most likely you have worn out pedal assembly. To check, first you can depress the clutch pedal all way down. Second release the pedal. Third try pulling the pedal up with your hand or foot. Your pedal is worn out if you can feel any movement.
You can fix this by adjusting the rod (temp fix). replace the whole pedal assembly. The best way to fix is to weld the end of pedal rod. I've done few of these.

To do it this way you need to adjust the upper switch up so the pedal is not hitting it also.

[iceminion]

Ok, im going to just start over and add dot 5 fluid with new mitsu GVR4 parts. (master/slave)

[Kracka]

Use dot 3 or 4 fluid, not 5!

[JET]

Yep, Dot 4 only. Ford Blue Dot is good stuff and cheap. Valvoline synthetic is decent too.

[Kracka]

For the clutch it really shouldn't matter since it won't be seeing much heat.