Evolution of a Carrera RST

[jpnovak]

Maiden Voyage Milestone!!! Such a great feeling. Congrats.

[quattrorunner]

So great!

[Uwon]

Some more pics. Another beautiful day in paradise!

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I still am wrestling with a few minor items including that non-working speedo. Engine runs really well but I still need to make some minor adjustments to the Eletromotive tec3r for the reground cams. The exhaust note is exhilarating!
Cheers,
Johan

[SpyderMike]

I like what you have done with that car...salute!

[quattrorunner]

Wow! Love the chocolate leather

[911 Rod]

Absolutely stunning Johan.
Will we be seeing you on the track with this new toy?

[flyn-hawn]

Wow, this is the first time seeing this thread for me and I see a lot of similarities with my car in your build, or vice versa as you started first. I wish I would have gone with the square weave as that was my plan C. I was talked out of the rolls royce wilton wool which was plan A and got a salt and pepper haargarn type which was my 3rd choice. Awesome build with superb detailing, the color is even pretty nice....

[Uwon]

The car has been driven around the block several times since finishing the build. Grearbox shifted nicely up to third and clutch operated as it should. Well, Tried to back out of the garage and clutch suddenly gave up. Could not get it into any gear-just ground the gears as if the clutch was not depressed at all.
Background: Clutch is almost new. Clutch cable is new. Everything else, I.e. clutch fork, trani etc. came out of the donor car. I just inspected and cleaned everything up before reassembly. Trani was not opened up-just replaced the oil with Swebco.
So I re-traced all my initial assembly steps:
1. inspected pedal assembly and front linkage in tunnel.
2. checked clutch cable seating at rear by tunnel. Cable sheath makes a nice metal sound against the clutch tube in the tunnel.
3. re-checked cable basic adjustment with cable disconnected at 1.2mm.
4. Re-set cable pre-load with cable connected at 1.0mm.
5. Re-set clutch release distance to 25.0mm (stop on floor board).
With the rear wheels off the ground, it will go into any gear if, and only if, the rear wheels are freewheeling. If I apply the brake pedal while I try to put it into gear with the clutch depressed, then it just grinds away.
I'm getting the feeling that the clutch fork has bent or dislocated itself from the pilot bearing.
Any ideas?
BTW, I have also posted this issue as a separate new thread so any suggestions that you may have should be posted there.
Clutch Suddenly Gave Up
Thanks in advance.
Johan

[quattrorunner]

I've never heard of the clutch giving up suddenly like that with only minimal use. Sounds like something else. Does it also feel differently? You mentioned the front linkage in the tunnel. I have had the set screw Allen thing back out on me a couple times enough that it wouldn't go into hears easily or at all. Looking at that, does it look loose?
Otherwise I can't help. I do know clutches won't usually just go one day to the next without broken tension springs or something.
Good luck I hope you figure that out quickly.

[Uwon]

Quattrorunner, just re-checked it-nice and tight. If it had unscrewed, I think that it would have shown up when I re-checked the clutch release distance.
I'm still stumped. Any other ideas?
Johan

[onboost]

Originally Posted by Uwon

Tried to back out of the garage and clutch suddenly gave up. Could not get it into any gear-just ground the gears as if the clutch was not depressed at all.

I'm getting the feeling that the clutch fork has bent or dislocated itself from the pilot bearing. Any ideas?

Thanks in advance.
Johan

Johan.. your problem sounds like the clutch fork.. fingers not in the T O bearing groove. Could be bent slightly or dislodged.
Sometimes you can lower the motor a bit, loosen the four bolts on the bell housing and inch the motor forward enough to see, or even correct. Its delicate in doing and maybe a PIA with so much in your engine compartment... just a thought however.

Good luck!

[Trackrash]

Have you checked the travel of the release arm under the trans as someone pushed on the clutch pedal? I would want to make certain that it is in the bell housing or not before proceeding.

[speednme1]

Sorry the hear about the clutch trouble...either way, you have a great build!

[wayner]

Mine did that and it ended up being a cracked fork. It just twisted every time I tried to use it instead of moving the bearing. Almost felt either like the cable being attached to nothing, or something solid. Very odd sensation but similar results.

[Uwon]

Ok guys, thanks for sharing my pain!
Not admitting defeat, I unhooked the cable from the release arm and got nice solid and smooth pressure when I moved the arm with the aid of a long screw driver. So, I then examined the arms and noted that the small one had a 1mm indentation where the adjustment screw rests. So I filed it off so I would get a better gap reading. I then reassembled and adjusted the gaps, tested the shifter before starting, started the motor and tried to shift-sounded like a first timer changing gears in a Model A crash box.
I would assume that since I still have clutch plate pressure at the release arm, the fork must be hanging on to the pilot bearing by one prong.
Tomorrow I'll drop the motor and trani and we'll no doubt have a surprise.
Cheers,
Johan

[Uwon]

Cracked clutch pressure plate!
Johan

[911 Rod]

Is the crack the reason for not being able to shift or the result from another failure?

[Uwon]

^^^ Think so. Fork is straight, no apparent cracks, and fits nicely into the clutch release bearing. Bearing is also nice and tight.

[KTL]

I would spend the $ for a replacement fork as long as you have it apart again. These forks old enough now that they're getting to the point hitting the fatigue life limit. We're seeing the broken fork issue pop up more and more nowadays. Broken clutch spring finger is not nearly as common. I've used & reused some rather old clutch housings and they are pretty darn durable. Still, nothing lasts forever.

[Uwon]

^^^ Kevin, yes, I had already ordered a new fork. Having read some of the issues, I thought that I should at least be pro-active because pulling the motor out is a royal Pita. I was lucky that it all happened in my garage!
I now want to know how to bench test the trani. Any ideas?
Johan