Recently I have started to notice a bit of a weird clutch issue on my car.

I currently have an ACT HD pressure plate on a sprung 6-puck disc, and have about 12k miles on it.

Randomly, when I go to push the clutch in to downshift, as I am trying to pull the transmission out of gear, it feels like the clutch is not fully disengaging. After I get the car into neutral and downshift to a lower gear, I notice the friction point of the clutch has also changed, usually engaging rather abruptly as I am slowly letting the pedal out to find the friction point. The next time I go to push the clutch in, it feels normal and it engages how it originally did, and behaves fine sometimes for the rest of the drive, or sometimes only until the next time I go to downshift.

This doesn't happen all of the time, only randomly it seems. When it does happen, I am generally always trying to downshift, so I am usaully braking or have been coasting in a particular gear. There are plenty of times where it doesn't happen while I am braking and downshifting as well.

My clutch master and slave were leaking slightly, and I replaced both with new genuine honda parts (the slave is an AP1 slave). I also installed a SoS braided clutch line to replace the rubber one. I bled the ever living shit out of the system when I put new fluid in after the installation. I am still having the same problem.

I figure if it were air in the system, it would be happening all of the time. The next thing I am going to try is to pull the slave off and rubber boot to check the clutch fork and make sure it is still lubed up and make sure the throw out bearing looks ok.

Beyond that I really am not sure what is going on. It doesn't seem to be crank walking, I can watch the crank pulley with someone else pumping the clutch and it doesn't move at all.

Any ideas?

 

I had a very similar issue that started about a year before I replaced my OE clutch. I didn't really think much of it because it would mainly happen when it was cold and maybe once every few weeks.

When I finally replaced my clutch, all of the components were actually still in good working order except the T/O bearing. It exploded. Maybe T/O bearing related?

 

If it only happens when downshifting from a high RPM, it might be a bent shift fork...

 

I had a very similar issue recently. My clutch (replaced) had 20K miles on it. One day at the track, shifting became increasingly difficult, then my clutch pedal stuck to the floor. After several presses on the cluth pedal, it finally came back up and seemed to act normally, the pedal that is, the clutch still diddnt seem to be fully engaging.
I thought I burnt up the clutch, but to my suprise, the clutch disk was fine, however one of the springs in the cluthc disk actually came out of its holder and was stuck in the pressure plate diaphram, not allowing the pressure plate to release (when letting the clutch pedal out)

Im really supprised because the clutch disk was an Exedy OEM disk. I am working with Exedy now to see if they will warranty the disk.

 

Well, it is intermittent on my car. It'll drive and shift fine except randomly when i push the pedal in it'll not fully disengage the clutch. The pedal comes back up though, and on the next clutch press everything will seem fine again.

I have ruled out hydraulics as the system has been bled properly and extensively, the master and slave have been replaced and are not leaking, and pedal has since been adjusted to allow for maximum piston travel (which didn't make a difference in my issue, but made the pedal feel better overall).

I am leaning toward something with the pressure plate, or something with the disc.. although I really don't want to have to drop the tranny again to find out :\