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Old 30-03-2014   #1
Join Date: Apr 2010
Location: Highlands
Posts: 318
Thanks: 27
Trader Rating: 0
United Kingdom 
LUK Suck's

I got no where with LUK as they back peddaled, denied all knowledge and blamed me.

So I tried to get an OE set. I found a supplier who could give me the Valeo DMF & repset.

Only, I simply could NOT find flywheel bolts to fit!

The Valeo DMF is much thicker, so requires longer bolts. But they have to be hardened, M12 x 1.25 and around 45mm long.

The LUK DMF uses the same bolts, only 25mm long as it has cutouts to allow the shorter bolts to fit.

My car was off the road for almost a week and the farcical show at Donald Mackenzie, FIAT, Inverness would have been hilarious if it wasn't so serious

So, in order to get my car back on the road, I bought a new LUK DMF & repset.

I DID discover something though...... The release bearing I fitted was 180 degree's out!?!?!

In my defence, I simply replaced as I found.

The release bearing from both LUK and Valeo have a little lug that seems to fit into a cutout on a prodruding bearing in the bell housing. However, the cutout prevents the bearing from fully retracting. This caused the clutch to not fully release (like sitting with it just above biting point).

So, having spoke to Mick B from Euro Car Parts (clutch expert) we agreed that my mistake was simply following procedure, but perhaps someone else had fitted the bearing upside down.

We came to the conclusion that as the clutch slipped, it wore down. This would have allowed the bearing to move forward and eventually fully release.

Anyway, so I fitted the LUK set, brand new flywheel bolts (I wouldn't not have) and fitted it all back together. Indeed, it went back together much more smoothly and the gearbox mated up first time this time.

Took it for a spin and immediately there was slip

So I decided to allow some time to bed in, like with new discs & pads. And it worked

I tried full throttle and up & down gears and she was fine, no more slippage





Except..... then the clutch started dragging

Reverse was a find it grind it affair

I took it home and parked, finding 1st was also find & grind.

I did it by the book. New DMF & clutch, new flywheel bolts with threadlock, new drive shaft bearing to replace a torn one, new shaft flange "O" ring to stop a leak and new sixty two pound crankshaft oil seal to stop a weep from the crank behind the DMF (it wasn't reaching the clutch, but better to prevent than cure).

So, what now?

The only difference I can see is the pedal is 5cm higher than the brake pedal, that's new!

It is possible the travel is too long, causing the cover plate fingers to catch on the friction plate, but that's a long shot.

I am still convinced LUK's parts are not right. They looked entirely different to the O/E Valeo parts.

Any comments welcome.
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Old 31-03-2014   #2
Join Date: Apr 2010
Location: Highlands
Posts: 318
Thanks: 27
Trader Rating: 0
United Kingdom 
Re: LUK Suck's

After speaking with Mick, I have decided to buy a new gearbox rear mount (it is worn, but not seriously so) and first, try new fluid in the master/slave cylinder (in case there is residual water or air in there) and if that works, buy a new slave as it is likely worn after 117k.

It could be 1mm of wear is enough to cause problems. It doesn't look worn, but it "is" plastic so who kows.

I still stand by my statement about LUK's treatment of me and will always in future try to avoid purchasing any of their stock
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Old 31-03-2014   #3
Join Date: Apr 2010
Location: Highlands
Posts: 318
Thanks: 27
Trader Rating: 0
United Kingdom 
Re: LUK Suck's

Inserted a washer in the "gubbins" of the slave cylinder and hey presto, it's all back on the same page.

Still got vibration, but can sort that out when the new mount arrives.
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