Whelp, hours of labor and my clutch setup doesn't work. Theres a weak grinding noise when I try to put in in gear with car running, regardless of where the clutch pedal is, and it WILL go into gear, but won't send any power to the wheels. Seems as tho the PP and clutch disc aren't interacting, or the input shaft and disc aren't interacting. I've used the following parts from Pinnacle Nissan:
4th gen disc 30100-40U14
5th gen PP 30210-89F00
TO Bearing 30502-41U20

I've read of several guys with/mentioning this setup (JSutter,Dave B, BigLou93SE) can't imagine why the parts would be wrong... if any of you guys are around, suggestions please!

 

i think there is a pressure plate cover that also goes with the 5th gen pp but i dont think that part would keep it from working

 

The 4th gen disk should work fine with the 5th gen cover... cant really say for sure, because I have the complete 5th gen clutch set up. Anyways, how did you put the pressure plate on?? Did you follow the proper tightening pattern and proper torque specs?? It is VERY critical to a properly working set up.

 

A pressure plate is a cover... they are the same thing. The 5th gen set up consists of a disk and a cover just like the 4th gen set up. The release bearing is the same for both.

 

JSutter has the fourth gen. clutch disk in the fifth gen. Pressure Plate, so that's not it. Likewise, through a mix up, Dr_Max has a fourth gen. PP and 5 gen disk...
I'm sorry I can't be of more help since I didn't do the install myself, but the pressure plate and disk combo is definately not the problem. Good luck with your re-install, I hope things work out.

 

On the clutch disk itself there is a marking that indicates the flywheel side and the pressure plate side. IIRC, if you put it on backwards the disk won't make make contact with the flywheel. That would explain why the tranny will go into gear, but won't move the car.

 

So what would happen if the pressure plate bolts were tightened too much or not tight enough??? I'm just curious....

 

Oh man I could not even imagine it fitting on backwards... like you said the cover would not be flush with the flywheel at all!

 

Yeah I remember when that mix up happened to Dennis... everything worked out for him though.

 

Probably what 1991tsi is experiencing... If the cover was torqued down too much OR torqued down unevenly, you would probably get some really bad contacting between the contact surface on the pressure plate and the contact surface on the flywheel... Off the top of my head, the max torque for those bolts is only 33 ft. lbs., so that is not really that tight.

 

its def. not the torquing of the pp, this is not the first i've installed, and its tight against the flywheel. even a loose pp would engage the disc to the flywheel enough to send power thru the tranny (until it was torn off). i'm wondering if my input shaft is just spinning in the clutch disc (wrong part, defective, etc). you'd have to be a real moron to install it backwards as the damping springs protrude from the pp side and wouldn't sit against the flywheel... calling Kenny Gomez tomorrow.

 

next question: how tight should the disc be inside the pp when installed. if i insert the alignment tool (i have a metal one) should I be able to move the disc around by hand?

 

well, sounds like you'll have to take your tranny off again, since I catch you in time, I like to tell you to also go behind the flywheel and change that rear main seal as well.

I didn't do mine, and it leaked shortly after I installed my spec stage 2 clutch and flywheel. now it's causing slips. So i'd have to change it again.

sorry that i'm not helping with the problem, but I thought this is important, too.