Technical Clutch alignment tool

[JumpJet]

Since I'm holding off diving into some Fiat projects thanks to an impending house move, I'm keeping myself busy with random other projects - one of them being a clutch alignment tool for our little cars. When the need to R&R the clutch arises, I have the fortune of having a spare input shaft to line everything up with, but many don't. I broke out the trusty calipers and have been dutifully reproducing the profile in order to produce a standalone clutch alignment tool. Behold...

The only catch is, that by taking a pause on the car, I haven't had a chance to truly test it out to make sure it does the job. I'm happy to share the STL/STEP if anyone wants to give it a go, but I can't promise perfection just yet. Or... if there's anyone in North America who may have a motor & clutch out at the moment, I can send you a prototype to test it out.

We as a community have been good about sharing the extra input shafts when the need arises, but if this tool works out, we'll all have ready access to one.

Thoughts, advice, etc...?

 

[PuntoHowTo]

I like this I recently put a new clutch in my mk1 Punto cabrio which uses the 1.2 16v engine used in many of the newer fiat 500s, same basic engine as the abarth etc, an my usual clutch centring tool was way too big to fit.

I managed to Jerry-rig my way through with a socket inside another socket and a little electrical tape, but I do have a 3D printer and this would have been perfect.

I’d defiantly like a copy of the stl file or you can upload it on something like Thingiverse for anyone to download

 

[JumpJet]

I like this I recently put a new clutch in my mk1 Punto cabrio which uses the 1.2 16v engine used in many of the newer fiat 500s, same basic engine as the abarth etc, an my usual clutch centring tool was way too big to fit.

I managed to Jerry-rig my way through with a socket inside another socket and a little electrical tape, but I do have a 3D printer and this would have been perfect.

I’d defiantly like a copy of the stl file or you can upload it on something like Thingiverse for anyone to download

I'll happily upload it to Thingiverse/Makerworld/etc, but only once I know for certain it works. I won't be able to test it until the next time I heave my motor out, but that may be awhile. Happy to email the STL to you if you want to DM me your email address.

 

[fiat500]

Since I'm holding off diving into some Fiat projects thanks to an impending house move, I'm keeping myself busy with random other projects - one of them being a clutch alignment tool for our little cars. When the need to R&R the clutch arises, I have the fortune of having a spare input shaft to line everything up with, but many don't. I broke out the trusty calipers and have been dutifully reproducing the profile in order to produce a standalone clutch alignment tool. Behold...

View attachment 481607

The only catch is, that by taking a pause on the car, I haven't had a chance to truly test it out to make sure it does the job. I'm happy to share the STL/STEP if anyone wants to give it a go, but I can't promise perfection just yet. Or... if there's anyone in North America who may have a motor & clutch out at the moment, I can send you a prototype to test it out.

We as a community have been good about sharing the extra input shafts when the need arises, but if this tool works out, we'll all have ready access to one.

Thoughts, advice, etc...?

Somewhere, I have an original Fiat clutch alignment tool, which dispenses with the splines.
That's a really helpful thing you have done there.

 

[PuntoHowTo]

I'll happily upload it to Thingiverse/Makerworld/etc, but only once I know for certain it works. I won't be able to test it until the next time I heave my motor out, but that may be awhile. Happy to email the STL to you if you want to DM me your email address.

I’ll drop you a dm, I would be good to see if it does fit the Punto, the clutch is pretty easy to get in and out so I could always drop the gear box off and test if for you if I have the time. The car is sitting on axle stands in the garage so it’s just a case of unbolting the gear box to get it off

 

[JumpJet]

Somewhere, I have an original Fiat clutch alignment tool, which dispenses with the splines.
That's a really helpful thing you have done there.

You know, I never really thought about it, but ya, the splines are rather superfluous in the design. So long as the outer diameter of the tool matches the inner diameter of the clutch it will center it up all the same. I guess I just modeled it after all the clutch tools I used to see in the auto parts store.

Hopefully this one works... if not, maybe I'll dispense with the splines as well.

 

[Mike1alike]

I never got to test it (and right now I don't know where I put it, but I surely have a top steering column somewhere) but I'm thinking that top steering column shaft should fit and be very useful there.

 

[fiat500]

You know, I never really thought about it, but ya, the splines are rather superfluous in the design. So long as the outer diameter of the tool matches the inner diameter of the clutch it will center it up all the same. I guess I just modeled it after all the clutch tools I used to see in the auto parts store.

Hopefully this one works... if not, maybe I'll dispense with the splines as well.

 

[JumpJet]

If you're willing and have the time, if you take detailed measurements, I'll whip up a 3D model of that (complete with embossed part numbers haha) and release it to the masses. We can all have a copy of the original! The models will allow 3D printing in metal or plastic, as well as milling if people are so inclined.

 

[the hobbler]

I never got to test it (and right now I don't know where I put it, but I surely have a top steering column somewhere) but I'm thinking that top steering column shaft should fit and be very useful there.

For those that do not have access to a"clutch alignment tool", as per Matt (Jumpjet), there is a very simple dodge for aligning the clutch centre-plate. Build up the clutch, both pressure-plate and centre-plate on the fly-wheel and centralise the centre-plate best possible with sockets etc, but leave the pressure-plate screw only just over'finger-tight.

 

[the hobbler]

For those that do not have access to a"clutch alignment tool", as per Matt (Jumpjet), there is a very simple dodge for aligning the clutch centre-plate. Build up the clutch, both pressure-plate and centre-plate on the fly-wheel and centralise the centre-plate best possible with sockets etc, but leave the pressure-plate screw only just over'finger-tight.

Part 2---sorry about that, my lap-top decided to "post reply" before I had finished-------with the clutch centre-plate only held on with the screws just over finger tight, but with the location-dowels engaged, fit the engine back in. Being that the centre-plate is (hopefully) about 95% aligned, and not being held in place by the pressure-plate, it will"sort-of" self-align" the final part. When the engine is in and secure, THEN tighten the pressure-plate screws up to the correct torque (12 ft lb--18 Nm). This method does work, because until was able to lay my hands on a spare spigot-shaft, this was the system that I used. HOWEVER---if you can obtain the correct tool (or Matt's version of it), then use it.

 

[fiat500]

If you're willing and have the time, if you take detailed measurements, I'll whip up a 3D model of that (complete with embossed part numbers haha) and release it to the masses. We can all have a copy of the original! The models will allow 3D printing in metal or plastic, as well as milling if people are so inclined.

That's a deal. Might take a while to do that though. I'm the source of the timing tool that was also made available for 3D printing, and I also see available on eBay. I don't think my head removal tool would get many takers....a bit of a luxury.

 

[The Panda Nut]

Ive always used my decades old dowel fron the valve grinding by hand days with tape round it to size. Its never failed yet.

 

[124BC1]

You know, I never really thought about it, but ya, the splines are rather superfluous in the design. So long as the outer diameter of the tool matches the inner diameter of the clutch it will center it up all the same. I guess I just modeled it after all the clutch tools I used to see in the auto parts store.

Hopefully this one works... if not, maybe I'll dispense with the splines as well.

I also was wondering if including the splines was necessary - all the clutch alignment tool kits I've seen to suit various sizes of clutch disc/spigot bearing didn't have any splines.

 

[124BC1]

I've often been able to centralise the clutch friction plate by using my fingers in the 3 gaps that are usually found on the pressure plate (clutch cover) and feeling if the disc is centralised with the cover bolts just tightened enough to hold the disc where I position it. (the disc is usually slightly smaller in diameter than the pressure plate).

Also, on some later FWD Fiats, there is no spigot bearing in the end of the crankshaft, so a normal alignment tool has nothing to enter into to align the disc and the pressure plate can't be left slightly loose and tightened after the gearbox has been refitted (as suggested by @the hobbler in post 10 & 11 above) as there is no access plate/space underneath the bellhousing. But iirc it is just about possible to access and tighten the pressure plate bolts via the small access hole in the upper part of the bellhousing that is normally used to view the ignition timing marks.

 

[puntodad19]

Or via starter motor hole ??

Might someone have dimensions of friction Plate hub "across the splines" minimum diameter please, also spigot diameter please ??

Will have to check end of crank for spigot "hole", Punto Evo 2010 1.2 8 valve...

Haynes manual shows g/box input shaft being spigotless and mentions hole in end of crank, but no dimensions it picture...

Thanks in advance for quick clutch job in the summer....

 

[JumpJet]

Or via starter motor hole ??

Might someone have dimensions of friction Plate hub "across the splines" minimum diameter please, also spigot diameter please ??

Will have to check end of crank for spigot "hole", Punto Evo 2010 1.2 8 valve...

Haynes manual shows g/box input shaft being spigotless and mentions hole in end of crank, but no dimensions it picture...

Thanks in advance for quick clutch job in the summer....

Might want to check the punto forum. This is the classic 500 one

 

[Pete O]

I see lots of comments with alternative methods of aligning the clutch; here's one for the brave- the mark-1 eyeball. The human eye is very adept at seeing eccentricity, if you look through the splines at the spigot you should be able to see whether it is concentric or not, maneouvre it with your fingers from around the outside, or with a big screwdriver in the centre, before tightening the pressure-plate bolts. I've done many different clutches simply by eye, including my old Ford tractor that has 2 clutches combined, i.e. gearbox and PTO clutch so has 2 friction plates to align with the spigot before the 2 halves of the tractor are walked together. Not much to be lost by trying this with a gearbox as lightweight as the 500.

 

[bugsymike]

Ive always used my decades old dowel fron the valve grinding by hand days with tape round it to size. Its never failed yet.

I have two of the SP clutch aligning tool kits in the metal boxes and as you say if an odd size I wrap insulating tap around it, I then went to the universal tool that holds the centre plate to the pressure plate once you have aligned it prior to installation, I haven't tried it on older multi spring plates only the modern diaphragm type.
Having said all this, as the OPs design is as near to original first motion shaft as possible which is what we all kept in the late 60s for a lot of various gearboxes and aligned with those as you knew the gearbox would slide straight in with no struggle. I have seen many idiots align clutches by waggling a screwdriver in the hole then try to force the gearbox on to the clutch with long bolts through to the engine and wondering why the clutch wouldn't disengage or was noisy.
All I need now these days is someone to lift the gearboxes for me.

 

[The Panda Nut]

I have two of the SP clutch aligning tool kits in the metal boxes and as you say if an odd size I wrap insulating tap around it, I then went to the universal tool that holds the centre plate to the pressure plate once you have aligned it prior to installation, I haven't tried it on older multi spring plates only the modern diaphragm type.
Having said all this, as the OPs design is as near to original first motion shaft as possible which is what we all kept in the late 60s for a lot of various gearboxes and aligned with those as you knew the gearbox would slide straight in with no struggle. I have seen many idiots align clutches by waggling a screwdriver in the hole then try to force the gearbox on to the clutch with long bolts through to the engine and wondering why the clutch wouldn't disengage or was noisy.
All I need now these days is someone to lift the gearboxes for me.

That for proper engineers... which Im definitely not! Im a bodger, but I try not to break things