Exedy Stage 1 Clutch Issues
 

I just installed a new Exedy Stage 1 Clutch in my BRZ and I'm having some issues.

First it chatters a lot when I run the car in neutral with the clutch out.
Depress the clutch and it's quiet.

Second after running on the track and heating everything up the following sequence blocks the car from going into gear:

1) Put the car in neutral
2) Let out the clutch
3) Depress the clutch
4) Try to put the car back into gear

When it's cold this sequence works OK.
If I shut the car off it immediately goes into gear.
Rolling forward with the clutch in also allows it to go into gear but I can feel things aligning as I push it into gear.

Any ideas on what's causing this and possible work arounds?

1. That chatter is from the throwout bearing.. I presume one came with the kit and you replaced it? Sure its properly installed?

2. Sounds like your clutch pedal needs adjustment and is not fully disengaging when the pedal is pressed.

It was professionally installed.
The throw out bearing was replaced as part of the install.
If it's the throw out bearing it would make noise with the clutch in and go away with the clutch out correct?

When the OEM clutch was in I adjusted my pedal down so as to not release at the very top of the pedal throw. Maybe this needs to be moved back up?

I would suggest having it professionally inspected. No problems with my Exedy stage 1. I've used both included TO bearing and OEM. Currently running OEM TO bearing.

I made no clutch pedal adjustments after my swap and everything works great. Good luck.

Sounds like it's no completely disengaging. Adjust you clutch so it engages further up from the floor.

The chatter may be normal, a lot of aftermarket clutches chatter. Adjust your clutch first though and that may solve both issues.

@alpine @marcoaferrer

Chatter is normal, unless its absurd and ridiculously loud. Aftermarket clutches chatter, I'm not saying you are, but I can't comprehend why people expect aftermarket clutches to not chatter. It's the nature of the beast. It's like installing stiffer motor mounts but expecting zero added NVH.

Locking out of gears, the clutch instructions call for this, might be something to consider:

"Lack of lubrication/dry splines will cause failure to disengage gears and also cause clutch drag.
Never over lubricate / grease the spline of your clutch disc as grease will splatter during rotation of the engine and clutch."

Source: http://www.exedyusa.com/multimedia/s...structions.pdf

I've never had a mild clutch setup chatter on me ever, including a sprung 6 puck, maybe a little more noise when rolling off the clutch from a stop..

IMO it should not be chattering at all when sitting in neutral.

I'm positive the pedal needs to be adjusted correctly, and you should have the chatter looked into.

In this car I've owned CM FX350, FX400, Exedy Twin Disk, Exedy Stage 2, drove two ACT 6 pucks and ALL of them noticeably chatter, specially in neutral and specially the hotter it is.

Although I'll say the Exedy Stg 1 being full face, chatter/gear rattle should be very minimal.

I'm having the exact same problem with my Exedy Stage 2. The problem only started a few weeks after installation, once it was broken in. It was installed by a mechanic. I took the car back to him to check the problem and he doesn't think it's the clutch but rather the synchros. His mechanic friend at Toyota says they've had a few cars come in for transmission issues.

Thinking about it now though, it won't go into any gear so how could it be all the synchros? I'm going to see him today to try new tranny fluid so maybe I'll talk to him about adjusting the pedal at the same time.

The clutch pedal should always be adjusted so that the grab point of the clutch is as low as possible while still disengaging the clutch. Having the grab point high only accomplishes overextending the pressure plate and eventually premature failure of it.

I think what the OP is referring to is Gear rattle. Most people, including myself, refer to gear rattle as clutch chatter. They are two different things though.

Gear rattle is what you hear when the car is idling and the clutch pedal is not pressed in and clutch chatter is sort of a skipping/hopping feeling when taking off from a stop. I believe chatter usually only occurs on pucked clutches.

Good point.

I wil say this then, parting from your post.


CM FX350 (8 puck)/400 (six puck):

Minimal chatter (skipping/hopping feeling when taking off from a stop)
A LOT of gear rattle (what you hear when the car is idling and the clutch pedal is not pressed in )

Exedy Twin Disk (2 full faces and spacers):

A lot of chatter
Mild Gear rattle

Exedy Stage two (8 puck) fixed:

Minimal chatter
Minimal gear rattle

The stage 2 isn't a full face. It's (I guess you would call) an 8 puck.