Clutch issues after engine swap

[SubiNoobie]

A little background:
Had/have a '91 Legacy FWD 5spd with EJ22 that I had done the clutch in about 3k miles ago. She was pretty beat, but ran and drove solid. I picked up a cheap 96 Impreza Outback Sport AWD 5spd with a EJ18 in it and a bad clutch (and from the gobs of oil everywhere, probably a bad rear main seal). I decided to swap my EJ22 with recent clutch into the Impreza. I'll spare you story of my trouble, but as it sits now, the EJ22 is running great in it. However, I cannot seem to adjust the clutch (Cable type) in a way that works.

The issue:
I am relatively new to the mechanical world, with only a few smaller projects (water pump, and a clutch) and this has been my biggest project. However, what seems to be my issue is that no matter my adjustment of the cable, the throwout bearing is still riding the pressure plate and resulting in the car not moving more than a few inches before it starts slipping hard. I pulled the engine and double checked everything, remembered that I had not installed the repair sleeve from when I did the clutch job on the 91 (still installed on the block I dropped into this 96-- didn't touch any of that). So I moved the repair sleeve over and redid the throwout bearing clips because one was hanging partially off. Reinstalled the engine and had the same slipping issue.

As you will see from the videos, I think there is something up with the fork, or the t/o bearing. I do not know. It seems I cannot keep enough tension on the cable to keep the pedal freeplay where it should be, but also not engage the t/o bearing on the pressure plate.The pictures are from this last time I pulled the engine after I adjusted the clips and put the repair sleeve on. This is how it was right before I dropped it back in and hooked everything back up.

I've attached a couple short videos and some pictures. If you need any additional information or pictures, just ask. I may pull the engine again tomorrow for further inspection and pictures. Quite frustrated with what should be a simple swap.


Clutch fork video 1

Clutch fork video 2

[Fairtax4me]

If you totally remove the cable from the release lever, and look down into the hole in the trans can you see the release bearing slide back and forth on the quill as you move the release lever? You should be able to see it move, and you should see it seat against the fingers of the pressure plate if you push back (toward the rear of the car) on the lever.

 

Were you able to easily slide the release lever on the quill before you bolted the engine and trans together?

Free play at the lever should be about 1/4-3/8". If you can move the lever at all, the free play is probably fine. If the cable is too tight you won't be able to move the lever either direction.

 

Is the rest of the driveline attached? Rear driveshaft, rear diff and axles all in place? Front axles are connected and in good shape?

Another thing that can cause a feeling similar to a slipping clutch is a slipping center differential, but that doesn't happen unless something in the transfer gears in trans is broken, or the rear driveshaft is gone, or an axle (any axle) or rear diff is broken.

[SubiNoobie]

Havent been able to check it out yet today. Ill grab some pictures tonight or tomorrow. Idk if it makes any difference to the possible issues you mentioned, but when i put it in gear and let out the clutch pedal it won't stall immediatly.