Here's the background.

Experienced Mechanic
06 IX MR 6 speed
New HDSS ACT clutch

I just put everything back together, the car fired right up, however the TOB keeps popping out of the clutch disk. I swear I had that thing pressed in TIGHT, but it keeps popping out.

Do I need to pull this thing back out, or is there some trick to get the TOB in the
PP ring tighter that I am not finding.

Thank you in advance for your help/suggestions

Just to clarify. The new clutch is in, the clutch disengages the first few times, then the TOB pops out of the clutch disk and the pedal falls to the floor.

 

does anyone have pics of the pressure plate wave washers and snap rings installed?

I am 99.9% mine are in right, but that other 1% is killing me

 

ok, well, looking round the site, I think I found the problem... can someone confirm?



is this the correct way the snap ring fits in between the "fingers" of the cage(meaning inside the small "fingers" and outside the large)?

If so, I am screwed. mine popped apart, and i installed the snap ring around the outside of ALL the "fingers" which could explain why my snapring isnt locking onto the TOB.

please advise.

 

Let me go shoot a few pictures for you. I will be right back.

 

As you can see it snaps in there. Without this ring the TOB will not work properly. This being a pull style clutch requires the TOB to be engaged into the pressure plate.

There is no way to install this without taking the trans back off. Wish I was lying but hey at least now you will be really good at it!

 

thanks for the great pics joe... thats exactly as mine is... the snap ring IS there, but I thought the small fingers needed to be outside the snap ring... I wonder why mine is not holding... perhaps I am not engaging it deep enough to "click" in

 

there is a round clip that you are missing to. thats what hold everything together.

 

nevermind. i didnt see it in the pic, sorry

 

All you should have to do is take the slave off and pull the arm towards the driver side. This will cause it to slide right in there as long as the ring is right.

 

I have the ACT HDSS clutch kit as well. When the pressure plate, etc. is bolted down and trans installed. I had a drop light shinning in the hole. You take your hand and trigger the clutch fork toward the driverside. Once you do that, you can visually see the TOB connect. It is really straight forward - you know if it is in or not.

When I installed the TOB in the trans, I played with the clutch fork making sure the arms will not slide past the guides on the TOB before installing it.

I take it your pressure plate is installed correctly? The only thing I can think of is that you might have damaged the snap ring causing the ring and TOB to not connect properly.

 

heres a few good pics in my thread.

https://www.evolutionm.net/forums/sh...&highlight=tob

 

Well, Thank you all for your help and support. Here's the resolution...

The TOB had just not pushed all the way into the pressure plate cage and snap ring.

After I got MitsuJoe's post, I went outside and levered the Hell out of the release fork (towards the driver's side). I then rotated the engine 180 degrees and did the same. Then I got in the car, pressed it in and out a few times, then started the car and the clutch engaged perfectly!

Before when I pressed the clutch pedal in and out when the engine was running, there was a definate vibration in the pedal. Once I pressed it in harder and tighter, and rotated the engine, the pedal vibration was gone.

I now have about 50 miles on the clutch with smooth driving, but many engagements, and the ACT clutch is PERFECT!

Thank you all so much for your help!

 

Glad to see you got it squared away!

How bad was the pedal vibration? Did it occur with the pedal pressed or released or no matter what?

 

The vibration was when the pedal was pressed down about 1" from the top then through the stroke.

As for how bad was it? it was pretty bad. what my theory is, is that the TOB was slightly in at a diagonal, so as it rotated, it caused pulsation in the fork which was translated to the pedal.

I am VERY happy with the ACT clutch now.. . zero lock out, and nice smooth engagement with very little effort.

 

That is interesting you say this. My drives wonderfully. However, I do have a slight vibration about 1" from the top of the pedal. This vibration is very minor and only happens at that point of the pedal (not through the stroke).

I watched my TOB snap into place but maybe its off just a little bit? Everything feels very nice with the clutch. The only thing is that slight vibration. Also, I get a weird rattle noise when the car is very cold that resides after 1-2 minutes of idling.