Evo9 Clutch Install Problems

[scheides]

Rosey's car has been a battle! We never did get the axles out of wheel hubs (link) but we did get the trans off, new clutch installed, and got the car all back together yesterday afternoon. Yippee! Pedal engagement feels fine, this is an Exedy Stage1 HD clutch, it looks almost identical to stock.

When you put the car in gear, and let the clutch out, it starts to lurch and maybe rolls 6 inches, then nothing. You can let the clutch pedal out all the way and it will make some noise like it is trying/starting to engage but it goes nowhere.

Troubleshooting:
-trans bolts are tight and trans is flush against block
-bled clutch/slave cyl, seems perfect
-TOB slides smoothly back and forth, clicked into place perfectly and lifts PP fingers as it is supposed to.
-completely unhooked slave cyl from clutch fork, put car in gear and bumped starter. Car goes nowhere. (this was a nailbiter but I had to try it).

Background/reminders:
-this is a pull-style clutch so by default it is engaged.
-flywheel was machined flat
-pressure plate was bolted down to spec (15 ft-lbs) and sits flush against flywheel


Todo:
-check xfer case alignment/flush to trans
-put car on jackstands, start car in gear, see if input shaft is spinning inside pressure plate


Side note: if anyone can lend a hand, its xmas and I have very limited time to work on this, late tonight or monday night are the only times I may be able to help Rosey. I'm leaving for xmas thursday and will be gone the entire following week through new year's. I'll have Mike post his number, the car is at my house.

[Matt D.]

I'm available to help any evening this week except Tuesday.

[scheides]

Put the car up on jackstands; all four wheels off the ground. Spinning the front left wheel does not affect the front right wheel (like it should) and if I start the car and put it in gear, and let the clutch out 3 wheels spin but the driver's front wheel does not. Thinking maybe that axle or maybe something with the intermediate shaft is goofed up/not installed correctly.

The front left wheel otherwise spins freely (by hand).

Xfer case seems to be flush with trans.

[Matt D.]

We've identified it as being the left front axle, seems as if the knuckle at the hub is either damaged or destroyed, with it assembled you can turn the hub by hand and it's crunchy and the axle won't turn.

Anyone have a front driver side axle and hub assembly available? We need both because the axle is seized inside the hub.

[cmspaz]

I know how I feel about this for my own car, but looking at vehicle compatibility, I can likely get my hands on a Precision hub assembly (seems this is shared with the 3/S VR4) at $190, and I'll look into an axle, which would be a brand new part, but would likely have to be ordered from the manufacturer. Text me tomorrow and I'll take a look.

[rose0529]

Originally Posted by Matt D.

We've identified it as being the left front axle, seems as if the knuckle at the hub is either damaged or destroyed, with it assembled you can turn the hub by hand and it's crunchy and the axle won't turn.

Anyone have a front driver side axle and hub assembly available? We need both because the axle is seized inside the hub.

Thanks for the help tonight matt.

We have the axle apart, and end of the axle that fits into the hub is disconnected and the splines on the shaft part of the axle are damaged. So I picked up an axle from Jim (thanks Jim!) tonight and we are going to try and combine the to axles to get it going again. I think we should be able to make this work and hopefully get my car back on the road tomorrow! Otherwise I'll end up trying to get the last part of the axle pressed out of the hub/knucle and see where we can go from there.

Originally Posted by cmspaz

I know how I feel about this for my own car, but looking at vehicle compatibility, I can likely get my hands on a Precision hub assembly (seems this is shared with the 3/S VR4) at $190, and I'll look into an axle, which would be a brand new part, but would likely have to be ordered from the manufacturer. Text me tomorrow and I'll take a look.

I'll keep you posted, but I think I can get one from Mitsu for like $130, it needed.

[FattyBoomBatty]

Air hammer. Trust me.

[mike55112]

Hub assembly is like 120 at mitsu, its more expensive at all parts stores.

[Kracka]

I'd personally go the new hub/axle route rather than piecing together an axle (balanced?) for a potentially damaged hub.