Brand new clutch - very chattery

[ot1138]

Hi everyone,

After many months, my project car left the driveway on its own! This is the first time it's done so since 2014, when a PO put it in storage.

In another thread, I recently documented the removal of the engine and replacement of the clutch. The new clutch is *extremely* sensitive. It seems to completely engage when the pedal is relaxed maybe 1-2" from the floor. While I probably could get used to that, the clutch is very chattery. When I switched to 2nd, the whole car was vibrating with the clutch fully engaged (I tried again and it wasn't so chattery, not sure if there's a pattern there yet as I've only driven it 500' or so).

I installed a brand new pressure plate, throwout bearing and disk. I used a clutch alignment tool when reassembling.

I'm wondering if maybe the clutch cable is too tight? Any other obvious things I could try?

[sjbartnik]

The free play at the clutch pedal should be 3/4" to 1"

The other thing that can cause chatter is if the bend in the Bowden tube where the clutch cable comes out of the chassis at the rear isn't right. It's supposed to have a sag in it of about 1.5" if I remember correctly (see Bentley). The correct amount of sag is achieved by placing washers between the end of the Bowden tube and its mount on the transaxle. Too much sag or too little sag can both cause problems.
_________________
1965 Volkswagen 1500 Variant S
2000 Kawasaki W650

[ot1138]

Thanks, I'll check that next.

I just dared to take it to the local gas station for a fill up. It seems that the chattering in second gear happens below 25mph... speed up a little and it goes away.

Another thing I noticed is that it is extremely difficult to get the car going in first gear. The engine doesn't seem to have enough power and as soon as you let out on the clutch, it cuts out.

[ot1138]

Another hint: It was unable to drive itself up on my lift in first gear. There is absolutely no power. As soon as it hit the ramp, the engine cut out.

[sjbartnik]

Clutch chatter generally only happens as you are engaging the clutch (letting the pedal out as you get moving). If it is happening after the clutch is fully engaged (foot off the pedal) then something else is going on.

Lack of power is gonna be an engine problem, not a clutch problem.
_________________
1965 Volkswagen 1500 Variant S
2000 Kawasaki W650

[ot1138]

Just checked the Bowden tube and there isn't much of a sag, neither are there any washers. I removed the clutch cable adjustment wingnut but the assembly is too stiff for me to remove the Bowden cable with the cable in, it seems. I guess I have to retract it from the pedal end?

Also how important is the seal for the end of the Bowden cable? I don't have one of those.

[ot1138]

Interesting - this guy suggests cutting a section of washers out and slipping them over the end of the Bowden tube to adjust it. Avoids the need to pull the cable.


Link

[74 Thing]

Just remove the bowden arm from the trans, then add some washers (3 or so), then bolt the arm back up and tighten the wing nut.

[Eric&Barb]

[ot1138]

As mentioned before, I am unable to get the existing Bowden cable out while the clutch cable is inside. However, I tried the trick in that YT video and it worked. I cut a couple of thick washers into horseshoe shapes, pulled the Bowden cable hard and slipped them in. It's a tight fit but I wrapped a bit of vinyl tape around them to be on the safe side.

I had a heckuva time getting the clutch cable readjusted after. I'd get it perfect, bring it off the lift, pump the pedal and found there was a bunch of free play. Thought I had it the second time and the same thing happened. Finally just kept tightening it up and the clutch is vastly improved. There is now only a bit of chattering while bringing it out of 1st and 2nd, and that goes away when the pedal is fully released. I suspect I could improve that by tightening up the adjusting nut a few more turns or perhaps inserting another washer.

I will start a new thread on the engine power problem. Thanks again for the help, everyone.

[sjbartnik]

[Eric&Barb]

[67rustavenger]

ot1138 started a new thread on tuning an engine.
It appears to be a higher HP engine.

Perhaps he has over powered his pressure plate/clutch grip capabilities.

Just sayin!
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!
Don't let your bad ideas remain, ideas!

[ot1138]