Clutch pedal incredibly stiff

Serfma

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'96 Cobra. A couple previous owners, somewhere down the line whoever did the modding was a moron. Clutch was terrible so we dropped the tranny and replaced:
  • Throw Out Bearing, CORRECTLY slid onto the spring of the new clutch fork
  • Clutch fork,
  • Pilot bearing,
  • Clutch disc,
  • Clutch plate,
  • Flywheel resurfaced
  • Everything torqued to spec and aligned properly.
Cable is not in a bind and moves freely through the sleeve when having an assistant pull back on the clutch cable while cable is being pressed. Pedal itself moves freely with cable not attached.

My current thought is that the clutch plate is incorrect. I have an 11" flywheel (says nodular on inside of flywheel, unsure what exact one I have), and I found out it's actually for an '05-'08, just that it's from a later model because I had issues with a clutch plate not lining up to bolt holes.

We had ordered an 11" from KY Clutch and it was incorrect. Took the one that came out of the car up and that's when he stated it's likely for an 05-08, just a later model in general. Got me a plate that lines up BUT i'm realizing now that the clutch plate fingers have a big play in why it is so stiff.

I was a big dummy and since it's my first time I made the mistake of not triple checking or thinking that the difference would matter. The TOP plate is the one that had the incorrect bolt holes. The BOTTOM plate is what came out of the vehicle and replaced by a new plate of the exact same, but is currently in the vehicle. As you can see, the fingers dip down and then back up near the end where the top plate's are straight and then raise where the TOB will press against.
72332796_3056125551124155_1811121467442593792_n.jpg


Now at this point I almost want to say for a fact that's my issue. If you guys do confirm also, would my best route be to see if I can have a custom one made with the fingers of the top plate, or is it something like new flywheel time?
 

Serfma

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Why are you using a clutch for an s197 mustang?

I'm a noob. I had no idea it was for an s197 Mustang until your comment just now. Flywheel is apparently from an s197 and previous owner had installed the clutch that I took out. (first project car, learning as I go) Took previous clutch plate to a clutch shop and explained the entire situation that I had no idea what's up, so he gave me one matching the old and didn't say hey something's wrong. :p
 

jman37

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I haven't dove into tr-3650 on an s197, but I remember reading the flywheel's are the same for the t-45's (maybe someone else can confirm) but I don't think the clutch's are compatible. Is it possible you got one for a tr-3650 instead of a t-45?
 

52merc

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My 01 has a Valeo made King Cobra 11" clutch from the factory with the TR-3650. I believe the earlier Cobras had the exact same set up but with a 10.5" clutch instead of the 11". Flywheels were the same (I believe). Not sure about the S197 flywheels.

The Valeo kit Part Number for the 10.5" is 52672003 (clutch, pressure plate, TOB, centering tool)

The Valeo kit P/N for the 11" is 52802015
 

Serfma

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I haven't dove into tr-3650 on an s197, but I remember reading the flywheel's are the same for the t-45's (maybe someone else can confirm) but I don't think the clutch's are compatible. Is it possible you got one for a tr-3650 instead of a t-45?

The clutch plate very well could be for a tr-3650. The flywheel is 11", which threw us off. I'm indeed running a t-45, stock is supposed to be a 10.5" flywheel but we have an 11" currently. The kit I got from KY Clutch has no P/N identifier anywhere. I'm unsure if the flywheel will even have a P/N on it (maybe on the rear side?)
 

mcaligiuri

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If your running a 05 clutch that’s why. The 05 up use a hydraulic clutch so yes it will require much more effort to engage. The 04 down clutch’s are cables so their fulcrum point will be different. Just get a complete new clutch setup and you will be fine
 

Serfma

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If your running a 05 clutch that’s why. The 05 up use a hydraulic clutch so yes it will require much more effort to engage. The 04 down clutch’s are cables so their fulcrum point will be different. Just get a complete new clutch setup and you will be fine

That's exactly what I was thinking. Was afraid of that. Just need a new clutch plate no? Not sure if I could have a clutch made with the pressure plate being the correct fingers. Lol. Not really into the idea of buying a new flywheel unless needed
 

mcaligiuri

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You need new clutch and flywheel unfortunately
That's exactly what I was thinking. Was afraid of that. Just need a new clutch plate no? Not sure if I could have a clutch made with the pressure plate being the correct fingers. Lol. Not really into the idea of buying a new flywheel unless needed
 

52merc

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Just buy this. Its the OE replacement. Perfect fit. A lot cheaper than some custom pressure plate that next time needs to be replaced will just a a PITA to someone.
upload_2019-10-20_17-1-2.png
 

Black02GT

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Just a thought I'd also check your input shaft. I had similar issues and ends up the 10 spline I had was tweaked. Coukd only tell when you REALLY looked at it but the clutch would bind up a bit.
 

Serfma

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Just buy this. Its the OE replacement. Perfect fit. A lot cheaper than some custom pressure plate that next time needs to be replaced will just a a PITA to someone.
View attachment 1605341

The issue is needing to purchase a flywheel too. It will likely not line up due to the flywheel also being from an '05 or above Mustang. So trying to save some money. hah.

Just a thought I'd also check your input shaft. I had similar issues and ends up the 10 spline I had was tweaked. Coukd only tell when you REALLY looked at it but the clutch would bind up a bit.

Yeah inspected the input shaft the first time we dropped the tranny and everything looks good.



Would it be stupid to convert the clutch to hydraulic?
 

ViciousBlack97

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This is just my opinion, but you're trying to engineer your way out of a problem that can be solved by replacing parts that were never designed for your vehicle. A standard flywheel will take all of the hassle out of your predicament and allow you to use off the shelf components instead of farming out custom fabricated parts that when their service life is up will put you back to square one as you search for a replacement. I'm sure there are more than a few stock flywheels circulating on eBay.
 

jman37

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^agreed. You want to convert to hydraulic, which would cost a lot, instead of just putting the right stuff in there.
 

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