beliblisk

iTrader: (16)

Hi there.

We were just installing full 6 speed conversion to my V6 impreza and all seemed to be ok.When the engine isnt turned on selection of the gears works just fine.

The problem occours when engine is running and i am unable to change gears like as master clutcs cylinder wouldt cope it.Seems as the clutch doesnt move far enough to free preasure plate.

Main clutch cylinder is OEM V6 one if that makes any difference.

Thing is that we need to sort the problem in 3 days as Bob Rawle is visiting Slovenia and i am scduled for remap.

Thanks everyone

tubbytommy

iTrader: (20)

have you put in the 6 speed clutch fork too? if not this could be the problem.

beliblisk

iTrader: (16)

Yeah the one i got along with the rest of the stuff

BrownPantsRacing

iTrader: (6)

Sounds like a clutch related problem to me rather than gearbox. Clutch fault could enable you to select gears when engine not running.

P20SPD

iTrader: (1)

Are you sure you have engaged the release bearing into the clutch properly?

tubbytommy

iTrader: (20)

yup i agree, clutch fork, release bearing, wrong clutch etc.
did you change flywheel and clutch to bigger six speed version?

JdcTypeR

iTrader: (19)

As above seems like clutch related, what's the pedal feel like?

jayallen

iTrader: (31)

Majita, on a side note......You have refilled the box with oil? I drained it before it was sent.

BrownPantsRacing

iTrader: (6)

Ah, this is the new owner of your bargain gearbox and clutch setup then jay! I'd have had this if I could have squeezed the cash at the time!

jayallen

iTrader: (31)

Its is yes..... All the way to Slovenia...

Majita used a new clutch tho because when i removed the box there wasnt a lot of life left in it.....I didnt realise the Flywheel was RCM until i removed it either so a nice little bonus for Majita.

beliblisk

iTrader: (16)

Hi guys.

Gear box and dif have fresh oil in it.Set up incudes RCM lightened flywheel and almost new AP organic clutch 6 speed one offcourse.Feeling of the clutch pedal as it should be.We also triple checked all items instaled.

We tried fitting other clutch and other master cylnder both with no effect.It seems as if fork wouldt push bearing far enough.We will also compare fork to another one tomorrow when we get a chance to disasamble another STI.

Really dont know what we gonna do if we realize all bits are ok but the whole system wont work

Thanks a lot for input

tubbytommy

iTrader: (20)

my guess would be clutch fork, i had a similar problem a few years back, with a bent fork on a replacement box.

beliblisk

iTrader: (16)

Yeah we bet on this one too.It is possible item got damaged during the transport(tho jay did awesome job packing it).Did you have the same symptoms?

Ill report what happens.

jayallen

iTrader: (31)

There is nothing wrong with the original fork with the box.

EDIT....I cant see anything getting damaged the way it was crated.

tubbytommy

iTrader: (20)

yes i had the same symptoms, the fork was bent slightly.
you could hardly see it.

beliblisk

iTrader: (16)

Jay i didnt ment nothing harm by it.I just said it might happen.You did pack it really good but no one knows for sure what goes on with it on the road

Like i said we are running out of options and this slightly bent fork is on the top of the list to check tomorrow.

jayallen

iTrader: (31)

I know you didnt fella...

tubbytommy

iTrader: (20)

it does sound like something simple and clutch related though, the box sounds fine if all the gears select when engine is off.
had me pulling my hair out for ages on mine, check clutch flywheel etc, then if all looks fine try a new fork.
i didnt think it would be that on mine but tried everything else and it turned out to be the culprit.

beliblisk

iTrader: (16)

Thanks again for the info guys.....we will try this one tomorrow and i hope it works

JdcTypeR

iTrader: (19)

Which way round have you got the bolt that secures the dogbone mount to the bracket on the gearbox as I've seen it put in round the wrong way and the clutch fork was hitting the threaded part of the stud so you wouldn't get full clutch pedal travel

Neil..

iTrader: (35)

Bleed the clutch system.

beliblisk

iTrader: (16)

Done that.

Will check that bolt tomorrow as well

sams300

im not sure but is the 5spd and 6spd slave cylinders differnet size/length. have you fitted a slave from a 6spd?

seen this fault on other gearbox conversions but im a noob to scooby conversions

LegacySTi

iTrader: (13)

defo sounds clutch related.

wats history of clutch pressure plate?

sani555

iTrader: (19)

Friend from Beliblisk here

We tried: - almost new AP clutch
- second hand clutch from working 6 speed car
- 6 speed slave cylinder (bled the sistem couple of times)
- change slave and master cylinder from other fully working car

The release bearing clips on nicely on the clutch cover.
Pedal has good fealing.

So have no idea where to look next if the problem isn't in fork...

Regards

JdcTypeR

iTrader: (19)

Did you get this sorted in the end?

beliblisk

iTrader: (16)

Sani555 and my self did some more gearbox lifting(good training for incoming Olympics,lol) and in the end damn thing finally pushed clutch from the flywheel.ATM shifting into 1st and reverse isnt as smooth as it should be (probbaly all set up needs few miles to settle in) but car is preped for tomorrows session with Bob

To sum it up it was a really strange coincidance from not bleeding cylinders properly to bad second clutch we put it,lol.

Thanks again every one

beliblisk

iTrader: (16)

It seems we aint out of the woods yet

Clutch pedal doesnt return to its place so i have like 2 cm of clutch duty cycle and i have some issues with shiwting.Any ideas?

Also,does any one ahve pics of 6 speed and 5 speed forks?

Thanks

Neil..

iTrader: (35)

Still sounds like the system has air in it to me, especially if the pedal isn't returning back its position.

prodriverules

iTrader: (52)

Try very slowing bleeding ie slow push of pedal and then lock off the bleed nipple when bringing the pedal back up and repeat that cycle,I had the old pedal sticking down and it took this bleeding method to get the air out of the system.