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Discussion Starter #1
I just installed a new stage 3 clutch kit in my 2003 zx3. I am having issues getting car into gear when pedal is all the way to the floor. The car goes into gear easy when I lift pedal off floor about an inch. Not sure if I have a bleeding issue or linkage problem. The car drives fine it just makes shifting difficult cause you want to shift when pedal is on floor and I need to remember to raise off floor slightly. I've bled clutch many times with no better results. Any ides would be very appreciated. Thanks
 

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You have air in the line Get a motive power bleeder or a mighty vac to "reverse bleed" the clutch only crack the bleeder a hair (just enough to allow fluid out) otherwise IT WILL SUCK IN AIR past the threads.

I like the motive power bleeder never had to reverse bleed

When you did the clutch I hope you did the clutch master cylinder at the same time otherwise you are setting yourself up for a leak down the road its a 25$ plastic part and a PITA to change and I always recommend changing it when you do the clutch......its a known weak link in the system

After you get all the air out you might also want to adjust the shift cable linkage look into the HOW TO section for a step by step procedure
 

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Might need a block on the floor....

Sounds like it's getting pushed too far, not too little. Was the friction plate symmetrical?

Push too far & it's contacting again almost sounds like contact to the plate hub area by the release bearing/pressure plate fingers. Out on a limb for a guess, but wrong way around on the plate MIGHT do that.
 

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Discussion Starter #4
Thanks for reply. I did buy the mity vac and I am getting multiple air bubbles. I must be opening bleeder way too far. I will try again and look at linkage adjustment. I have read that you shouldn't mess with linkage cause its hydraulic clutch. I will have to do more reading I guess.
 

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Discussion Starter #5
Yes that's exactly how it is. I push to floor and it engages again. When you say friction plate do you mean flywheel? I had that all resurfaced.
 

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Discussion Starter #6
When putting together clutch kit I made sure I had the right side towards the flywheel. You hit the problem right on the head sailor. What do you mean by a block in the floor? Hope I don't have to take transmission out again!
 

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Friction plate is just that, the plate with friction pieces on it that goes between the flywheel & the pressure plate.

Center hub of that usually has a front & back side, I'm just taking a WAG (Wild A$$ Guess) that if it was backwards it MIGHT be contacted when pedal is fully down (release bearing/clutch fingers contacting).

Never seen this happen myself, just trying to add up what could possibly happen to match the symptoms. Haven't seen any clutches with different release cylinders/bearings, so that wouldn't change. Slave & release bearing is a single unit on these as you'd know.
 

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I was making a poor joke, and a possible suggestion to make it useable at the same time.

A LOT of cars have a round plastic button on the floor for the clutch pedal to contact when it bottoms, something like that to limit travel might work for you. Problem remaining then would be how to make the safety switch work without the pedal all the way down, or just bypass it for now.
 

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Discussion Starter #9
Man I'm pretty sure I put that friction plate in correct. I don't think pressure plate would of fit on if it was backwards. You sure got me thinking though. So my problem would not have anything to do with linkages right? I do know it is that my pedal goes to far and engages clutch again as you said.
 

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Haven't seen the pieces, could well not fit at all backwards.

There isn't any adjustment to a linkage, it's only a pedal & the hydraulic cylinders so there's nothing to change there. Hydraulics auto adjust clearance & the movement is a function of the master/slave cyl. sizes.

Try the tech. line of the Clutch mfr., they may have info. we don't.

Stop block to reduce travel might actually be your answer, sounds like it'd work from your description.
 

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Discussion Starter #11
Hey sailor thanks for all the help or at least getting me to think about possibilities for a fix. I ended up looking under dash at the rubber stops for clutch pedal. It seems they were all mashed like someone had a heavy foot. I bought this car needing a clutch so I didn't think of that. I took some 1/4 inch rubber and cut to the size of the original bumper and glued it on not allowing the pedal to go that far down. I did same thing with safety switch and all seems well. Thanks again. Your joke actually got me thinking a different direction.
 

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Great! An easy fix.

Kickin' around ideas is the best function of the Forum IMHO when it comes to repairs. When you're stuck for ideas any thoughts about how it works might lead to a solution.

Best part about working in a shop was when ideas ran out we had someone to throw out possibilities handy, this takes the place of that.
 
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