Today I installed a new Excedy single-plate clutch/cover/flywheel on my 93' WRX. Everything went fine from removal to reinstallation, but when I went to put the car into gear to back out of the garage, the clutch pedal went straight to the floor with no resistance, and stayed there until I pulled it back up by hand. I immediately thought it was a symptom of having air in the clutch line, so I bled the system, even though none of the lines were disconnected during the replacement. Still, same. Then, I thought it could be that the throw-out bearing didnt engage the pressure plate and get locked in properly, so I went about undoing everything I just did and pulled the tranny out again. The bearing was in the pressure plate like it should be, so that wasnt The problem. After doing a lot of measuring using micrometers and feeler gauges, I determined that everything I was installing was about 2-3mm (from flywheel to pressure plate) thinner than the stock set-up, and I put everything back together again, but this time, I used the stock pressure plate along with the rocket clutch and lightweight flywheel. It worked, and I drove home. Strange thing is, all these parts came as a kit, and everything installed without a hitch... could 3mm really make that big of a difference, or could the problem have been caused by something else.... possibly something installed wrong? The throw-out bearing was pretty noisy, so I am going to break it all down again to change it, and I want to put on the Excedy pressure plate this time. Please help!

 

Thanks! Ill give it a shot. I know what you mean about "pumping up" the pedal. After we reinstalled the whole deal again with the stock pressure plate, the pedal went to the floor again, but the second and third time pumping it, it went back to a normal feel.

Anyways, after some *****ing and moaning at the speed shop clerk who sold me the flywheel/clutch package, I found out that the 93-94 year WRX stock trannies were different and needed the Excedy throw-out bearing to accompany their pressure plate. Its a pull-type pressure plate, so the only thing I can imagine is that the stock bearing is too long for the travel of the clutch forks, and wont pull on the plate before the actuator is fully extended. I guess ill see here in a couple days if that is it or not.