tbpom1003

Hi guys, so I had my first clutch replacement done just now, and I started the car. I followed the diy guide from s2ki, first result showed in google.

I used ACT HD PP, ACT 8lb flywheel and OEM friction disk.


Problem is, I cannot shift into the gear with the engine on, harder to gear in with engine off than before. It seems like I'm trying to gear in without pressing clutch pedal.
I noticed that the clutch pedal has dead zone for the half of the travel. The pedal goes in without any effort for the first half way, and then I can feel the resistance.

Here is my guess, (1) OEM flywheel have tabs which prevent the pilot bearing pressed in too far. However, ACT flywheel doesn't have those tabs, so I just pressed in the pilot bearing from the back, even to the back surface of the flywheel. Maybe should I press it in more?

(2) I pressed the end of the clutch slave cylinder before I install it back. would that cause this problem?

Any guess where I messed up please?
Thanks in advance

Also, my flywheel is kinda touch something located left upper side on engine housing. Does anyone know what it is? is it a sensor?

[attachment=68958:S2000_flywheel.jpg]

Slowcrash_101

Starter?

tbpom1003

you mean the thing on the engine housing??

noodels

Thought i read somewhere about clutch fork popping out of place..

quote:
you mean the thing on the engine housing??
<yes thats the starter motor housing>

Aurex

Clutch bled properly?

T/O Bearing fork issue?

I would check these first. The S2000 clutch is backwards from most of the vehicles I have owned, in the sense that the T/O bearing is pulled out not pushed in.

tbpom1003

Thanks I'll take off the slave cylinder and check the clutch fork!

btw, is it ok the starter motor housing is touching the flywheel?

Slowcrash_101

Not touching but it's supposed to be there, how else will you crank the car? Push starting it?

tbpom1003

yeah, i mean if it is not supposed to touch the starter housing, what I received from ACT is manufactured wrong. that's why I was wondering

windhund116

Is the outer diameter (including starter engagement teeth) of the new flywheel the same as the original one? Thickness of the overall flywheel-pressure plate assembly? Same disc style and rearrangement of alignment pins for the pressure plate? Gear mesh the same?

Yeah, it seems something is wrong with that aftermarket flywheel. If you check the two side-by-side, you may find the problem.



Good luck!
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noodels

also would look at the gear stick install <shifter in car> can be fitted incorrectly
https://www.s2ki.com/s2000/topic/772...shifter+grease