Exedy Stage 1 Clutch Issues

[marcoaferrer]

I think the dust generated from break-in is causing the contamination of the grease. This is my guess since the first 200 miles of break in the car drove flawlessly.

[wparsons]

Originally Posted by qtwre

Because this is the most expensive option for someone who doesn't have the facilities to drop the tranny himself.

I can't speak for the OP, but in my case this problem came up after a few weeks with the clutch. I wonder if there was too little grease and it became contaminated with filings and dust. It seems like a bad design to require lubrication that will eventually become full of dust (and therefore stop lubricating.)

Take it back to the mechanic...?

As for the design, all clutches work this way. Until someone comes up with a way to have the clutch work well without needing to float on the input spline of the transmission they'll continue to work this way.

Now maybe the Exedy ones have super tight clearances or something, but the basic design is extremely common.

[mike the snake]

Gremlins

Originally Posted by marcoaferrer

I think the dust generated from break-in is causing the contamination of the grease. This is my guess since the first 200 miles of break in the car drove flawlessly.

[qtwre]

I spoke to Steve from Exedy tech support this morning. I told him that my mechanic did grease things during install so Steve had a strong feeling that it has more to do with the pedal and getting full disengagement. On their test car they had to adjust the pedal a bit to get full range out of the master. He said if it was his car, he'd look at the pedal again, but I told him my mechanic adjusted it in both directions quite a bit, so he suggested maybe bleeding the fluid.

Should it come down to it, I took some notes as he explained his steps for installing the clutch:

• Clean input shaft with wire brush.
• Apply grease to input shaft. It needs "high temp" grease like axle grease, which is what's in the packet that came with the kit. Not brake grease or something else I forget.
• Slide clutch disc on and off multiple times to get grease in spline hub of disc. It should slide freely.
• Grease will build up on sides of disc. Wipe off. (So I guess enough grease should initially be on the shaft that sliding the disc will scrape it off)
• Then install assembled clutch

If anyone does end up refitting the clutch, he said to look for red dust mostly on the disc, and maybe some on the shaft. That would indicate insufficient lubrication.


Between this and my tuning issue I'm really not enjoying my car, which is the opposite of the point of having it.

[marcoaferrer]

Tell Steve to take his thumb. Clip the nail so he doesnt get cut, then shove it up his ass until he looses his watch.

We've had people bleed the pedal, and I have adjusted mine up and down in 4000 increments.

Its not the pedal. Do you trust that your mechanic did a sufficent job of adjusting your pedal? Cause Im sure he wanted that to be the solution to the problem. Im sure he would rather adjust your pedal then have to drop the tranny again just to lube a shaft. Im sure your mechanic did his best to properly adjust the pedal. I did my best to adjust my pedal (Im not a pro by any means) and many others have adjusted their own pedal in every direction in hopes of a solution.

Steve sounds like a tard behind a desk that knows how to read the Exedy FAQ page.

ps. my douchyness isnt directed towards you or anyone that doesnt work at exedy...

[wparsons]

Originally Posted by qtwre

Between this and my tuning issue I'm really not enjoying my car, which is the opposite of the point of having it.

I know this isn't going to be helpful at all, but that's always the risk when you start modifying things.

[romin]

I adjusted my pedal this past week and was able to get back into gear after exiting from a hot track this weekend. The neutral, clutch out, clutch in, and back into gear sequence wasn't smooth but I didn't get locked out.

[qtwre]

I had my car back to my mechanic last week. He removed the clutched, cleaned everything up and reapplied grease as instructed by Exedy. He also flushed the clutch fluid and had previously adjusted the clutch pedal for more travel. So I think that covers just about every adjustment.

It still isn't great. It will sometimes lock me out and sometimes doesn't want to come out of gear so easily. At this point it either is the worst part of break-in (I still don't have much mileage on it) or there is something wrong with the clutch itself. Maybe tolerances. My plan is to just keep driving it to see if it gets better with age. If it isn't better by the time the car goes away for the winter, I'll be talking to Exedy again about warranty.

[romin]

I heated my clutch up on the track this weekend and got locked out again after a clutch in, neutral, clutch out, clutch in, sequence. Even rolling forward wouldn't get it back into gear. I ended up shutting the car off and then it went right in.

So much for the pedal adjustment.

[jdnguyen]

I had this same problem with my act clutch. The issue was fixed after cleaning and re greasing the input shaft and replacing the TOB. Also to note, upon inspection my pressure plate and flywheel were slightly warped. This will all be replaced shortly and I'm going with the exedy stage 1 with oem flywheel and oem TOB

[Scenic Driver]

Originally Posted by jdnguyen

I had this same problem with my act clutch. The issue was fixed after cleaning and re greasing the input shaft and replacing the TOB. Also to note, upon inspection my pressure plate and flywheel were slightly warped. This will all be replaced shortly and I'm going with the exedy stage 1 with oem flywheel and oem TOB

Don't be surprised if it stops working properly in 1-2 thousand miles. I recently got rid of an act clutch.

[jdnguyen]

Originally Posted by Scenic Driver

Don't be surprised if it stops working properly in 1-2 thousand miles. I recently got rid of an act clutch.

I expect it too. Which is why I gave an exedy on its way


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[Scenic Driver]

Originally Posted by jdnguyen

I expect it too. Which is why I gave an exedy on its way
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I went back to all OEM. In my car the act pressure plate was damaging the TOB, I think it's just too strong for the TOB/clutch fork arrangement in this car.

[jdnguyen]

Originally Posted by Scenic Driver

I went back to all OEM. In my car the act pressure plate was damaging the TOB, I think it's just too strong for the TOB/clutch fork arrangement in this car.

I agree. I'm replacing everything. Clutch fork, pivot ball and going to oem flywheel and TOB with the exedy stage 1


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