pzookey Posted November 26, 2016 Share Posted November 26, 2016 Interesting topic title but fairly true. I put new head gaskets along with a new clutch and dropped the engine back in. Everything went together quite well until I put the slave cylinder back on. Is was not making contact w with the fork. I then made a mistake and hit the clutch pedal one time. Slave cylinder popped out and now is pretty much shot. The problem comes back to what appears to be a mis adjustment on the fork but no adjustments were made. Just a new clutch set installed. I did pull the motor back out and pull the clutch and compared to the old one. Throw out bearing, Clutch and pressure plate all look correct. It has to be something simple I am missing. Does anyone have any ideas? Quote Link to comment Share on other sites More sharing options...
montana tom Posted November 26, 2016 Share Posted November 26, 2016 I would look closely at the throw out fork , they have been known to crack. Quote Link to comment Share on other sites More sharing options...
pzookey Posted November 26, 2016 Author Share Posted November 26, 2016 I did not see any cracks but it had started to get dark by the time I got the engine pulled back out. I will look in a little bit when I get back out there. Anything is a possibility. Quote Link to comment Share on other sites More sharing options...
pzookey Posted November 26, 2016 Author Share Posted November 26, 2016 Just checked and no cracks in the throw out fork. Time to look into some other things. Quote Link to comment Share on other sites More sharing options...
lmdew Posted November 26, 2016 Share Posted November 26, 2016 How much movement do you get out of the fork? The slave cyl should be able to be put back together as it's just a seal cup. You will then have to bleed it. If you clipped the throw out bearing to the fork, there's really no where for it to go. Quote Link to comment Share on other sites More sharing options...
Mikevan10 Posted November 26, 2016 Share Posted November 26, 2016 Sorry, no specific suggestions on the clutch issue. But you only said that the salve cylinder push rod was "not making with the fork". Do you mean it was not aligned properly? Also, how would the slave cylinder be damaged by this mishap. I would think you could reassemble it and bleed the system. To be honest, what I am more curious about is your head gasket issue. How many miles on the engine and what were your symptoms, if you don't mind? Mike V. Quote Link to comment Share on other sites More sharing options...
pzookey Posted November 26, 2016 Author Share Posted November 26, 2016 everything was aligned with the slave cylinder rod and fork. There was a gap between them. I may be able to pop the slave back together but with 253,000 miles on it I may just replace. The head gaskets are the typical 97 2.5 issues except they had been replaced once before. The head bolts were not torqued properly as they came out way too easily. Symptoms were loss of coolant on drives of over 1/2 hour. Bubbling through the coolant recovery tank after driving was the dead giveaway. My daughters 97 did the same thing only she did run hers hot. Still running but still a possible issue in the future. Quote Link to comment Share on other sites More sharing options...
Mikevan10 Posted November 26, 2016 Share Posted November 26, 2016 OK, now I see your info that shows the car to have 202,000 miles, The reason I asked is because my '97 with 285,00 miles may be developing head gasket issues which is not common on this particular engine type. Quote Link to comment Share on other sites More sharing options...
Mikevan10 Posted November 26, 2016 Share Posted November 26, 2016 Ah, ok. You went for the 2500. Gotcha. Quote Link to comment Share on other sites More sharing options...
forester2002s Posted November 26, 2016 Share Posted November 26, 2016 Is there any resistance on the top of the clutch fork when you try to push it by hand? Or does it feel loose? Quote Link to comment Share on other sites More sharing options...
pzookey Posted November 26, 2016 Author Share Posted November 26, 2016 Just got home from Christmas tree shopping and I took a quick look at the fork and throw out bearing. Checked the slave cylinder mount and my best guess is that the fork came off the ball stud mount. I will try putting it back together again tomorrow. Quote Link to comment Share on other sites More sharing options...
pzookey Posted November 26, 2016 Author Share Posted November 26, 2016 Is there any resistance on the top of the clutch fork when you try to push it by hand? Or does it feel loose? It was loose yesterday. I will find out more tomorrow when I attempt to put the engine back in again. Everything else looks good. Quote Link to comment Share on other sites More sharing options...
pzookey Posted November 26, 2016 Author Share Posted November 26, 2016 Engine is back in the compartment. Clutch works but slave cylinder is leaking. Tomorrow will be the day of truth. Bolting everything back up and testing. It appears the fork came off of its pivot the first time around. Quote Link to comment Share on other sites More sharing options...
pzookey Posted November 27, 2016 Author Share Posted November 27, 2016 Everything is back together and working, well sort off. Running on 2 cylinders with a P1507 code. Clutch works, engine started and idle was stable as it could be with 2 cylinders, test drive was good except for lack of power. P1507 is for the IAC but I think the problem might be with the Neutral safety switch. A little digging when I have light will be in order. Quote Link to comment Share on other sites More sharing options...
pzookey Posted December 4, 2016 Author Share Posted December 4, 2016 P1507 was from a vacuum leak from a broken port on the vacuum switch on top of the engine. Newer battery and a set of new tires and it runs like a scalded dog. Quote Link to comment Share on other sites More sharing options...
pzookey Posted December 10, 2016 Author Share Posted December 10, 2016 Drove it to and from work all week. 80 miles round trip. Still running great. 25 mpg running down the road. New slave cylinder is here so since the old one is weeping I will go ahead and change it. Quote Link to comment Share on other sites More sharing options...
idosubaru Posted December 10, 2016 Share Posted December 10, 2016 Neat feeling engine all apart then all those parts are moving and running! Hydraulic clutches can be annoying to bleed. Quote Link to comment Share on other sites More sharing options...
pzookey Posted December 10, 2016 Author Share Posted December 10, 2016 Luckily this was the second 2.5 I have done. The first one is still running down the road. I had to bleed the clutch after the slave over extended and yes a bit of a pain but no worse than one of those silly ford ranger slaves that sit around the input shaft of the trans...... Quote Link to comment Share on other sites More sharing options...
pzookey Posted December 23, 2016 Author Share Posted December 23, 2016 Well the old Roo is still running like a scalded dog. Running the 80 mile round trip to work everyday with no issues. From the sound of my daughters 97 I may be doing an engine swap. I can't get it through her head to check the oil every gas fill up. She lets it get three quarts low on a regular basis. I already told her I would be billing her for the spare engine. Quote Link to comment Share on other sites More sharing options...
sparkyboy Posted December 23, 2016 Share Posted December 23, 2016 Good work man! If your daughter breaks her car, make her do most of the engine swap! Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.