Still at it, sorry. Hard to work on the car, and traveling for work at the same time. The clutch fork has arrived, so I will try to compare side by side to check if thats the problem.

Those of you that mention adjustment, my post said the clutch has already been adjusted as far as I can, and still nothing.

 

UPDATE:

A friend (colonel fox) and I got the trans down yesterday, and inspected a few items. First, the clutch disk had pretty uneven ware. One side of the disks are more worn than the other side. The disk closest to the engine seemed to have the most ware. I contacted Exedy, and they said the clutch may have hung up, and told me to lightly lubricate the input shaft when I reinstall.

Second, I cannot eyeball whether the fork is bent or not. It looked okay, but we all know looks can be deceiving. I will try to measure the to teeths compared to the new one.

Third, I had though the TOB bearing may have gone bad becasue the clutch sounded much louder...wrong. TOB was in perfect condition.

Lastly, my fluids looked really clean, so I don't think fluid has anything to do with it. FYI, I'm trying out a brand called Fuchs Silkolene 75w90 this time around. Previously ran Amsoil with great success.

 

Good info, once you have everything put back, let us know if problem are gone

 

hey bud, any updates after re-installed

 

I want to break-in the new clutch disk before I make any statements. So far though, it seems pretty good. First gear is "normal" again, and all the other gears shift ultra smooth...prolly a result of the new fluids. Reverse is still a bit tough, but its not as hard as before.

Here's something I learned from some research for those running an Exedy Twin Disk. May not be my issue, btu interesting nonetheless.

Straight for the guys at Jack Trans:

"We have noticed a problem with the Exedy twin disk units for the EVO 8-9 that people are mistaking for a trans problem. If you are using an Exedy twin disk clutch, please note some have a problem of sticking at idle when the clutch is depressed which will cause the trans to feel terribly notchy when shifting into gear from a stop. This is happening due to insufficient floater plate to basket clearance. The floater is cast and the basket is not. The difference in materials cause the assembly to stick when the vehicle warms up as the parts are expanding at different rates, so the floater will not let go of the disk and cause a low RPM clutch drag issue. To prevent this problem we recommend the following before installing our trans when using the Exedy twin disk:

1)Disassemble the clutch assembly.
2)Polish the area on the basket that makes contact with the floater (the arms).
3)Polish each side of the arms around the basket thoroughly.

This will prevent the floater from sticking by adding more clearance and a nice polished smooth surface for the floater to make contact with. When done correctly, your new trans will shift perfectly at low RPM!"

 

You have changed both to new Disks? Using same pressure plate?
It seems like clutch/install related issue.