New Clutch, still slipping???

[lmdew]

I picked up a 93 Impreza sedan 1.8 AWD for the Daughter to learn to drive the manual trans. The PO thought it needed a clutch. I drove it about 5 miles home and it acted like it was a clutch problem.

 

I did the clutch yesterday, the old one did not look that bad (should have been the warning sign). New Exeedy Clutch pressure plate and Bearings. I did not turn the flywheel, but dressed it with 80 grit and my orbtial sander and checked it for flattness.

 

Put it all back together and its doing the same thing?

 

The clutch cable adjustment is all the way to the end of the cable, which I though was a little strange.

 

There was about a 1/4" between the pressure plate and flywheel with the new disk before I bolted up the flywheel which is normal.

 

As I was putting in the drive shaft (rear wheels on the ground) I could rotate the drive shaft going into the rear diff.

 

Could the rear diff be shot and that's why the car is acting like the clutch is slipping?

 

If that's the problem is the trans AWD viscous coupling also shot?

 

Somethimes things are not as simple as they seem (another garage day) :>)

 

Thanks Larry

[RallyKeith]

What did the flywheel surface look like? We just had one where there were slight ridges on the internal and outer edges of where the clutch makes contact to the flywheel. These ridges made a brandnew disk and pressure plate still slip.

[lmdew]

No ridges, flat from side to side, I took off what little glaze there was with 80 grit.