Technical Panda 1.2 Dynamic Clutch Operating Lever Alignment

[Shuggie]

The clutch operating lever on my Panda 169 1.2 Dynamic (part 46761574) appears to have a vertical alignment mark as shown below. There is no mention of it in any reference that I can find; and in theory it is not possible to misalign the lever on the clutch operating fork (part 55250936) since the splines of the fork pivot have a cutout that presumably matches a raised part in the operating lever's corresponding splined hole, but I'm curious.



My reason for asking is that the original AP clutch on my car went very stiff and all was lovely after fitting a new Ridex clutch kit round 8 months ago; however that new clutch also became stiff after a few months (the original AP clutch pressure plate and release bearing both showed signs of significant overheating), so maybe the clutch has been 'over engaged'? For reference, the entire clutch hydraulic system has now been changed using LuK parts; and while that made for a smoother pedal, the heavy action persists. Also, note that the clutch operating lever moves freely in both directions when the slave cylinder is disengaged. The clutch is not noisy and it operates smoothly and progressively, but I know from two expert opinions that the heavy pedal action is not correct.

A new LuK clutch kit is being fitted this week, along with a new (Original Birth branded) operating fork, so I'm hoping that will be a permanent cure.

Any thoughts?

 

[koalar]

No there no alignment or adjustment

The lever and fork only fit one way

The fork can and do wear on the end

There is a wear indicator on the flywheel

The original AP have the nicest feel

But none should be stiff, I fitted the cheapest transmech which works fine

Without being there it's hard to tell, my best guess is the flywheel is worn down or the release bearing isn't clip in properly

Did you fit the correct size, there's two, yours is close to the crossover period

Did you degrease the splines, deburr them and sparingly apply the new grease and slide the plate down them and then wipe any excess off

 

[koalar]

Here's what the lever action should look like on a fairly new clutch

 

[Shuggie]

No there no alignment or adjustment

The lever and fork only fit one way

The fork can and do wear on the end

There is a wear indicator on the flywheel

The original AP have the nicest feel

But none should be stiff, I fitted the cheapest transmech which works fine

Without being there it's hard to tell, my best guess is the flywheel is worn down or the release bearing isn't clip in properly

Did you fit the correct size, there's two, yours is close to the crossover period

Did you degrease the splines, deburr them and sparingly apply the new grease and slide the plate down them and then wipe any excess off

The flywheel looked absolutely fine with no obvious wear, and yes, the Ridex clutch was the correct size - obviously so when mated to the flywheel. I cleaned the splines with a wire brush and cloth, and then greased using a specific clutch grease (Sachs, iirc). The Ridex clutch works fine, but I want to understand what made it go stiff, just like the original. The clutch fork was not replaced, even though I knew it was recommended, simply because we ran out of time. I suspect that was my mistake.

This time, I'm not doing the clutch replacement myself, even though I rather wanted to, but it's cold outside - the work is being done by J Dain in Norwich who are transmission specialists who gave me a very fair price for fitting the new clutch. Interestingly, Dains said that they only fit LuK clutches, so it's entirely possible that the Ridex clutch going stiff is simply a matter of quality and you get what you pay for (hardly any less between Ridex and LuK, though). At least with all new hydraulics, a new clutch fork and a quality LuK clutch kit, there's the best chance of it all being perfect this time.