<VV> New Clutch Isnt Working

[Steve Brennan]

My Spyder sat in a carport in Anaheim California from 1974 to 2005.  In
spite of this, it ran quite well, and I used it to teach my 17 year old
daughter how to drive a stick shift.  We then got it painted and a new
interior put in, and I decided to put a Kevlar clutch in just to play it
safe.  The old clutch worked quite well, with no slipping, but once my
daughter wanted the Spyder as "her" car, I just figured that I would err on
the side of caution.  Plus, I had never dropped a Corvair drive train, so I
thought it would be an interesting project.  

As for the details you ask about, let me admit up front that my memory is a
bit fuzzy on this stuff because I did this work in June of this year (I
spent the intervening months soundproofing the engine compartment, changing
the rear axle bearings, and powder coating the shrouds, fan, pulleys, etc.).
That said, if I recall correctly, I installed the pilot bushing using the
transmission input shaft, as I was using Bob Helt's book as a primary guide.
I also recall reading that a deep socket of a specific size worked to tap
the bushing in, and I believe I used that technique to confirm the bushing
was all the way in.

Anyway, if I knew then what I know now, I would have realized that the
bushing could present a problem, because after using the input shaft to
install the bushing, I had a heck of a time getting it back out.  So I
cleaned everything up real good and worked the shaft into the bushing until
it released more easily.  I am embarrassed to admit that I really do not
recall testing to see how easily the shaft spun in the bushing.  Frankly, I
thought that any tension would quickly be removed because the bushing was
oil impregnated brass.  Rookie mistake.  

As for other potential problems, I do not recall any problems with the
clutch hub binding on the shaft.  I do, however, believe I did have to close
the gap between the differential and bell housing  by tightening up the
bolts.  Unfortunately, it has been too long for me to really be sure.  

All other clutch engagement parts appear to be working well, and I do not
believe I bent the disc. I see no evidence of any cable or pivot problems,
everything appears to adjust as it should and, as I posted previously, I
have been able to watch the throw out bearing sliding into the pressure
plate through the use of a mechanics mirror placed in the starter hole.
That is one reason that I have been so perplexed -- everything looks like it
is working perfectly.  But for whatever reason, I can't put the car in gear
when it is running: when trying to put it in 1st 2nd or 3rd gear, the
shifter just won't go into gear.  4th and reverse, on the other hand, will
allow me to attempt the connection, only to be met with a very determined
synchro grind, i.e., those gears are not even thinking about slowing down.

As for posting pictures, if you or anyone else can tell me what
parts/images/angles might be of use to a trained eye, I will take them and
post them.  But right now, I just can't figure out what I can show.  That
said, I agree with you that if I do drop the drive train again, I really do
not know what I will be looking for, other than perhaps a very tight or
seized pilot bushing.  Still, it appears I have run out of other options.

I appreciate very much all the thoughts and suggestions you and others have
shared.

Steve

-----Original Message-----
From: Chris & Bill Strickland [mailto:lechevrier at earthlink.net] 
Sent: Sunday, November 25, 2007 7:48 PM
To: virtualvairs at corvair.org; Alohaz at ca.rr.com
Subject: Re: <VV> New Clutch Isnt Working

From: Shaun McGarvey <shaun_mcgarvey at shaw.ca>

>It IS the bushing, Steve.
>  
>
not necessarily, imo, unless Steve used the same tool Shaun describes -- 
this is why they make bushing drivers, to drive bushings -- I'd never 
recommend using an unmodified "stub shaft", if that is what I think it 
is, to install the bushing -- just a deep socket would work much better 
than said shaft.  My opinion is that if it is tight enough to bind up 
the input shaft, it should have presented a noticeable difficulty in the 
assembly of the transaxle to the engine.

>When installed, they mushroom slightly, closing up the inner diameter just
at the end where you hammer on. When I install them, as a last thing, I pull
out the stub shaft I use to drive them, most of the way out and then wallow
out the end slightly to restore the proper hole size, checking with the
input shaft for no tightness.
>
Steve, did you beat the pilot bushing up during installation?  after 
installation, did you check it for clearance with the tranny input shaft 
you actually used in the assembly?  I experienced similar problems a 
long time back with a damaged clutch hub that bound on the shaft, and 
now I always check the hubs for internal damage and an easy fit on the 
shaft.  Did you have to force the bell housing up to the block by 
tightening the bolts, or did it just  freely all slide home together, 
like it should?  Did you "bend" the disc by hanging the transaxle 
unsupported off the engine (generally not seen on Corvairs when the 
entire drive train is removed).

There are so many things that could be wrong, you will only know for 
sure by doing it over, but first, why did you initially replace the 
clutch? Was it slipping, chattering, or not releasing? Did you do other 
work and just thought you'd replace the clutch while you had it apart?  
If so, what other work was performed?  Is the clutch cable in the early 
stages of failure mode and stretching?  Is a weld on an arm somewhere 
breaking? Is it an early or a late? Is one of the pulley wheels 
failing?  Did you inspect the pivot point in the clutch arm for wear -- 
I've seen them actually worn through.  Et cetera.  Or any of the other 
things that have already been mentioned ...

Maybe post your pictures up to a website and let some more experienced 
folks take a look.  The problem with a do-over for you is that if you 
don't know what went wrong the first time, the likelihood of fixing it 
the second time around is  somewhat diminished.

Godspeed!

Bill Strickland


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