Clutch problems

[Nelpy]

Hi

I’ve been having clutch problems for a while now - pedal going hard then soft, pedal moving up and down against my foot, clutch slipping, jerking, popping out of gear etc. etc.

I’m looking for some pointers on what to try next. I’ve just replaced my slave cylinder which I realised was leaking and sucking in air and dirt, so thought that would solve it.  After putting the new cylinder in it over-extended and popped apart on first use.
I realised that the pushrod from the new cylinder was much shorter than the old one (presumably the person who converted the van before me put in a longer pushrod to make it work) The piston was having to come right out of the end of the cylinder to reach the fork.
I replaced the shorter pushrod with the longer one and it seemed to work ok - until I gave it a test drive and the clutch started slipping badly. I thought that maybe the longer pushrod was not leaving enough room for the fork to come back fully and so not letting it completely engage the clutch. I replaced the pushrod again with another one that was in between the two lengths and this seemed to give it enough travel either way so I assumed that would solve it. On trying it out the clutch is still slipping like mad, jerking and popping out of gear.
The hydraulic side of things is all fine - new master and slave, new lines. No air in the lines and no fluid leaks. I’m thinking of putting the shorter pushrod back in and putting a shim/spacer on the clutch fork so that it makes contact sooner and doesn’t have as far to travel but not sure if this will really be any different from changing the length of the rod. I’m at a bit of a loss now - any advice on what to look at next?

Thanks,
Neil

 

[Aidan]

Neil
so you have a non standard engine installation and you give no information about what bellhousing and clutch and flywheel set up you have without which we can't give any advice

Has it ever been right ?

[Nelpy]

I don’t have any info on the clutch setup to be honest - the van was converted to Subaru before I bought it and the person who did the work passed away so I can’t get any info. The gearbox is a Subaru 6 speed TY756, but not sure about the clutch. It was fine when I bought it but has had intermittent problems over the last couple of years - so maybe never been 100%.

Was really just wondering generally what other causes of slippage could be if not the slave cylinder.

[Aidan]

Probably best to contact Nick Tune he knows a good deal about the scooby box install options and pitfalls and set up, I only know about the original van boxes I'm afraid.
Nick may have done the conversion