new clutch slips :(

Guys,

I just installed a brandnew kevlar clutch in my 4runner. The clutch is
from southbend clutch and sports a 1600 lbs pressure plate.

Now that the clutch is in the first thing i notice is the clutch pedal
is soft as butter. pressing it in feels as light as the gas pedal.

the truck rols but the clutch slips at any serious rpm.

I wonder what the problem can be? I had the flywheel ground. Could it
be too thin so that the clutch doesnt engage? but still .. why is the
pedal so soft?

Is there any spec about how thick the flywheel has to be before it
doesnt work anymore (the 4runner wheel has a bump for the clutch disc
and the outside is recessed)..

Advice appreciated

Matt

(xpost)

wrote:
> Guys,
>
> I just installed a brandnew kevlar clutch in my 4runner. The clutch is
> from southbend clutch and sports a 1600 lbs pressure plate.
>
> Now that the clutch is in the first thing i notice is the clutch pedal
> is soft as butter. pressing it in feels as light as the gas pedal.
>
> the truck rols but the clutch slips at any serious rpm.
>
> I wonder what the problem can be? I had the flywheel ground. Could it
> be too thin so that the clutch doesnt engage? but still .. why is the
> pedal so soft?
>
> Is there any spec about how thick the flywheel has to be before it
> doesnt work anymore (the 4runner wheel has a bump for the clutch disc
> and the outside is recessed)..
>
> Advice appreciated
>
> Matt
>

If I am understanding the setup correctly, it sounds like the pressure
plate bolts to the flywheel on a plane that is different from the
wearing surface that actually engages the clutch disc. If that is the
case, when resurfacing the flywheel, it is necessary to machine the
surface to which the pressure plate bolts, as well as the wearing
surface - and there is a spec as to what the difference between the two
should be. Good news is that if this is your problem it's easily
fixable by a good machine shop. the bad news is that you will have to
R&R the clutch again.

This can also happen on a Volkswagen, or so I've heard (never actually
had it happen to me, but I have been warned in the past)

good luck,

nate

Another alley to check will be the bolts that secure the pressure
plate. If they are shouldered bolts, in some cases refacing the
flywheel will shorten the recesses that the shoulders go into enough so
that the shoulders bottom out in the holes before actually tightening
the plate down, resulting in your situation, a slipping clutch. The
cure is to put in new, non shouldered bolts.

to all: thanks for the replys and help!

I took the clutch out and it looks like the disk is too thick by about
1 mm... the manufacturer is takeing it back for examination ...

I picked up an Aisin disc to run the truck in the meantime...

Matt