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Problem FIXED

Well, 10 hours yesterday (Saturday) and I am HAPPY to write the EPILOG to this dilemma.

I measured the travel of the throw out bearing, and took off the trans cover, and made a wood block spacer equal to the travel when the clutch pedal is depressed. I was able to now inspect the clearance between the disc and the pressure plate.
There was none.....
The "warp" in the disc was causing the drag. I had to use channel lock pliers to turn the input shaft with the clutch in the 'release' position. It did not turn really hard, but there was noticeable effort required to turn it. Certainly enough drag to prevent getting it in gear...

Took it all back apart, and put the disc on the input shaft between to shaft collars to capture it on the shaft.
I managed to straighten the disc. Actually, I got it very straight
and running true. I did not think I would be able to get it back that straight, but it worked out really pretty good. There were a couple spots that were 'kinked' but I put it back in the truck with the pressure plate, and the wood spacer to check again.

Those 2 spots did drag......BUT now I could turn the input shaft by hand with just some slight drag! I could also feel the 'stickiness' or 'grip' of the fluid when I was turning the input shaft. I marked those spots on the disc and took it back apart again.....for a second go-round.
Got those spots bent back as well, now the disc is really looking straight! Back together again, and very little drag with the ability to wiggle the disc between the PP and flywheel.

I also put the pressure plate in the hydraulic press on a flat plate, and checked the travel and the flatness of the plates adjustment. It was flat within about 5 thousandths all around, which is not surprising considering the PP looks 'like new'.

Well, I re-assembled it all again, and started it up....WAY way better! I am able to shift from neutral to any gear with just a bit of gear 'grind'....not any big deal, and from one gear to another it is silent. I think the slight bit of grind is typical of these transmissions, and it's just a gentle pull on the shifter and it 'bumps' into gear.
WOW......finally!

Apparently, the bit of 'warp' that -was- in this disc was causing the problem from the start, and the 'extra' warp I put in, made it worse.
The disc was not sticking to the flywheel and this was not a case of oil 'suction'. It was the drag from the 'warp'.

I don't know if I will change the oil from Dexron II to type F or not. Maybe down the road a bit....
I'd like to learn more about the difference between Dexron and Type F.

THANKS for all the reply's, ideas, and suggestions on this problem!

dan k
  • Posted 4 Mar 2013 07:02
  • By dkmc
  • joined 18 Oct'09 - 48 messages
  • New York, United States

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