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Hi All,
My 01 EX coup friction disk appears to have exploded after less than 25K miles. While driving around town the clutch just gave out. Back in 2020 I had an ASE mechanic replace the clutch (Exedy ?) etc. The flywheel was resurfaced. Upon investigation, I found the slave cylinder spring broke. I've replaced both master and slave (Exedy) and now I can get in and out of gear with the engine running but there is vary little grab from the friction disk. The transmission bell housing has a bunch of fibrous stuff in it like kevlar or carbon fiber.
My question is: Would the slave cylinder issue account for the friction disk problem or is something else wrong ?
I'm attempting my first DIY clutch replacement so thank you for all the tips and info here.
Last edited by JeffD95070; Aug 24, 2024 at 02:46 PM.
Reason: problem understood.
Pulled the clutch today. Both the clutch and the pressure plate say Exedy on them. I checked against the Exedy global site for counterfeit and they appear legit.
The clutch was engaged while coasting downhill causing the facings to burst through extreme shock.
Gear being shifted down when the vehicle engine is revving lower than the transmission ratios, resulting in excessive RPM at the driveline end. This is beyond the capacity of the burst strength specifications of the friction material.
Lack of free travel caused by faulty clutch slave cylinder or air over hydraulic system (common in Japanese truck applications). With a new clutch kit installed keeping in mind the diaphragm tips/release lever tips are further down due to the thickness of the new clutch disc. The slave cylinder piston will now be operating further towards the end of the cylinder where it has not worked for some time, depending on adjustment and travel. This area in the cylinder may possibly be corroded, again keeping in mind that brake fluid is a hydroscopic liquid, which is very absorbent of moisture and moisture corrodes and could result in the piston jamming and not returning, therefore, causing the release mechanism to activate the clutch in a semi disengaged position.
Driver resting foot on clutch.
Lack of free travel and proper adjustment.
Wrong differential speed selected to match with chosen gear (trucks with 2 speed differentials).
SOLUTION
Driver education for 1, 2, 4, and 6.
Check clutch release mechanism, air system and hydraulics for 3.
Adjust clutch to manufacture's specifications for 5.
"
Here is a shot of my slave cylinder:
So I think "Lack of free travel caused by faulty clutch slave cylinder ..." fits my case and answers my original question. I never noticed any problem with the clutch until it broke.
Moral of the story: If you're going to go through the trouble and expense of replacing your clutch, replace the master and slave cylinders as well. They are not that expensive and you have to bleed the system anyway. A vacuum bleeder makes quick work of that.
