General Another broken clutch thread

[levemircento]

Well, today was finally the day I had to do my clutch, I have been adjusting it nearly every day lately to allow me to put it into gear, and the screeching from it was also getting worse.

Luckily, I had already bought a clutch kit off ebay

And armed with my laptop in easy reach of the car, and the Guide that Tabblink182 wrote, I set to work.

I seemed to struggle "popping" the gear control rods off, I was only a few mins into the job and my patience was wearing thin.

So, after counting to 10, then 100, I tried again, success - anyway, lets just skip the rest and come to the part where the gearbox came free of the engine

Initially, when the gearbox fell off, this is what I was greeted with:



Those clutch pressure forks [or whatever they are called!!] dont look too happy!!

I undid the bolts holding the cover to the flywheel, the plate fell out....

I now need to know, before I continue refitting, which way round the new plate fits, I didnt make a note before it fell out onto the floor

Two more clutch plate pics:



Not great eh?? Seems that the outer part of the release bearing was pressing the forks, with no part of the actual bearing being used, and this is what has worn away the forks.

Attention was now aimed at the release bearing:

on gearbox:



Look at all the bits on the bottom of the bellhousing

And here it is on the floor, clutch side up:



And the back of it




Gotta say Tabblinks182 guide was very helpful

However, like I said above, I need to know which way the new plate fits on, before I get the 'box on and all done up, then find it to be wrong.

Rain stopped play, perhaps that was a good thing, with my pending enquiry.

 

[rallycinq]

Lumpy side away from the flywheel.

Cheers

D

 

[levemircento]

Yeah, i thought that too, after closer inspection of my first pic up there

I attempted to put the box back on this afternoon after making my post above, I have a big trolley jack supporting the engine, mostly because its back wheels are buggered and it wont move about easy

However, I found that I could not manage to get the box onto my smaller trolley jack by myself, the gearbox is sodding heavy and downright awkward to do anything with, I can get the g/b into the right place on the floor, but then it needs tipping towards the engine to get a jack under it, and my big jack is then in the way of that - and of course, its supporting the engine so I cant move it.

Am just hoping my mate can get over here in the next couple of days to help me out, he lives 20 miles away, he has a nice Sealey trolley jack with a big pad which will help a bit, and I also wondered about trying to use a 2" ratchet strap from a bar above to help lift it into place.

I knew getting the box back in was gonna be tricky, but its getting it lifted up there in the first place thats stumped me already

 

[fingers99]

In so far as there is a trick to this, use one of these to support the engine (although a wind up type axle stand is good, too) and something like the end of this to hold the gearbox steady -- quick fab job to fit onto a trolley jack -- otherwise your hands will be too busy trying to balance the box on the end of the jack.

 

[rallycinq]

The big trick with the box refitting, is NOT to touch the clutch release arm while heaving the box about. It is all to easy to move the arm through a large arc (no, not you Arc) and dislodge the release bearing from its seating on the fork.

Cheers

D

 

[fingers99]

And the other big trick is not to drop it on your head!

 

[levemircento]

The big trick with the box refitting, is NOT to touch the clutch release arm while heaving the box about. It is all to easy to move the arm through a large arc (no, not you Arc) and dislodge the release bearing from its seating on the fork.

Yeah, I had sussed that one out, annoying isnt it? I just fixed the bearing back in and used a cork rubbing block pushed between the arm and the [reverse light?] switch/connection, to hold the arm in the open position, I can see that its another thing in the way but I dont want to get the box in place then realise the bearing had dropped out and onto the floor!!

 

[cc1]

As long as you used a clutch centering device, then the box should just slide on.

 

[levemircento]

As long as you used a clutch centering device, then the box should just slide on.

yep, I made a centering tool up, the cover and plate are fitted, and my mate is coming round in the morning to give me a lift with getting the 'box back on

 

[rallycinq]

Once you've got the box back in, you need to remove the reverse light switch to get the reverse cable back in.

Cheers

D

 

[levemircento]

Once you've got the box back in, you need to remove the reverse light switch to get the reverse cable back in.

just got the box in this afternoon, about 2 hours [maybe more] of constant swearing and stress, luckily I had some help theres no way I would have been able to do that by myself, NEVER AGAIN!!!

I have yet to connect everything else up, so thanks for the info rallycinq

 

[rallycinq]

Putting box back in is one of those really annoying jobs where you can huff and puff four ages and then all of a sudden it pops straight in.

My luck usually means that if the box pops in straight away, then I've forgotten something. like the release bearing.

Cheers

D

 

[levemircento]

Yeah, I found using a long bar under the box to lever it worked better than anything in the end.

I made sure the release bearing stayed put, by wedging the lever in the fully off position with a cork block

 

[Diwiak]

what mileage your clutch went off??? Ihave hard pedal and quiet strange sound from gbox, but dont have a mood for another "fix it again tommorow" - how did u find your clutch is ready to change??

 

[levemircento]

what mileage your clutch went off??? Ihave hard pedal and quiet strange sound from gbox, but dont have a mood for another "fix it again tommorow" - how did u find your clutch is ready to change??

Its about 55,000, I have done 5,000 in it, and I would say that the last 3000 have had clutch issues, issues that were fixed just by a quick re-adjustment, until last week that is, when she made a grumble and refused to go in gear at all!!

But looking at what I removed, I dont think its the original clutch.
The car was sold as new in the centre of London and spent 49,000 miles there, I have all the docs to back up the mileage, London = traffic = clutch eating!! although thinking about it, I have no docs that refer to a clutch being fitted so who knows.

 

[Diwiak]

too soon - i have almost 62k, dublin traffic, so will go away too

clutch should last longer, doesn't it??

 

[levemircento]

Well, its all back in and working now

The difference in how the clutch feels is amazing, really smooth take up, and a nice light pedal feel.

Gotta say though, its probably the hardest job I have ever done on a car, I think it may have been easier if the engine was dropped with the box attached, well, never again!!

One thing though
When I started the car back up, it idles very high [1500rpm], but its really smooth and drives perfect.
I didnt disturb any connectors other than the reverse light switch cable, just in case I pulled the loom while accessing bolts etc I checked the temp sensor [blue plug] on the back of the inlet, on firmly, so is the lambda connector.
I didnt disconnect the battery, although the g/box earth lead was undone - and fastened back up.
Ideas?

 

[Diwiak]

some temp. sensor???? but if you didnt touch anything, dont know.. rallycinq will tell you he knows evertyhing

what about ecu reset???

 

[levemircento]

I tried an ecu reset, well - I pulled the plug out for a few seconds, back in and still the same

I have a feeling I have snagged the wires to the lambda - while engine idling at that fast speed, I pulled the lambda plug and there was no difference.

I have driven it this evening on a 10 mile round trip and still no difference

 

[Diwiak]

measure them with some voltmeter