Jolly Green Monster

iTrader: (4)

Finally got around to changing the clutch after it has been slipping under WOT for the past 4,000miles on occassions..
Turned out we believe to be the original clutch!
Which I will take a pic of but haven't yet.. not much left on it and the studs were level with the friction surface or the other way around in fact. No flywheel damage but small amount of surface cracks on the pressure plate.. Fitted a new crank seal and flywheel/layshaft bearing.

Probably took about 16hours work! :OMG: but was on axle stands and my first one.. (lame excuse).. but took my time and it is done!

No major problems it just fought all the way through.. nothing ran smooth with out at least one hiccup.. biggest mistake was to push the box up to the engine too fast and without making sure it was lined up correctly.. ended up dropping it back off and trying again slowly and ensuring the engine and box were lined up..
Only other this I did and then went "oh bu99er!" was to fit the thrust bearing to the pressure plate and realise it would have been easier to fit that onto the gearbox and put it together surely?? but managed to fiddle the fork in anyway.

I am bruised all over and ache like made and just turned the bath black!

Some pictures anyway:

The car


Intercooler off:


Start motor removed, and looking at half shaft spring clips..
Also cam cover leak! doh! something else to do next!


Down pipe off / close up on turbo very orange (not just rust) optimax?


Dropping off the wishbone etc to remove the half shafts, only did one side then moved the box over to get the other off:


The gearbox splitting:


Oops it feel off the jack! only kidding, flipping heavy though!


New borg and Beck Clutch, not bad for £85 notes with 3year warrentee:


Flywheel off, not back for 124,000miles..


Permission to have a rest now?

Cheers

JGM

[Edited by Jolly Green Monster - 5/20/2003 9:55:13 PM]

Jolly Green Monster

iTrader: (4)

I'll resize the pictures if I get the chance.. gone a bit big..

Nothing but a paste on the gearbox plug.. no chunks.. not bad for the miles.. I must be to nice to my clutch and gearbox..



JGM

[Edited by Jolly Green Monster - 5/18/2003 9:52:55 PM]

Rich TurboUK

Well done JGM!

Glad I don't have the only mental mileage Scooby (135,000)... Will be doing mine soon, so good to see you getting stuck in!
You never know, this might cure your mystery running problem as well...

Rich

Jolly Green Monster

iTrader: (4)

Tick over still going low after WOT run.. strange..

Noticed exhaust was blowing and there was a pipe off of the charcoal canister.. neither of which cured the strange tickover..

Will take the idle controller apart soon.

No clutch slip anymore though

JGM

P20SPD

iTrader: (1)

Well Done Simon, sorry if i was not much help on Saturday when you rang.

dnb

Well done.

I hope you're right with the first one being the worst! (I've only done one & I hope it's going to hast a good while...)

Jolly Green Monster

iTrader: (4)

No problem Steven, I was getting stressed with it at the time and then annoyed at the inadequate manual I was using.. which failed to mention undoing the clutch release fork with the allen plug and then no torque settings.. you saying "flipping tight" was prompt enough to do just that.. I did them to 85Nm in the end.. much more than that and I think they would have sheered..

Dnd, I think I'll put off running my own rally team now

Diff oil and engine oil to do today!

Cheers

JGM

David_Wallis

i did show you how to release the clutch arm..

Ooops I should have mentioned the release bearing..

David

Jolly Green Monster

iTrader: (4)

David,

Yes I printed out the thread from 22b and followed what you said there for the relase fork.. thanks.. was just shocked that the Subaru manual missed it out!!

As for putting the release bearing into the back of the pressure plate.. when I released I thought I'd see how hard it would be to remove it, on the old one.. after 10minutes and loss of skin I thought f*ck that I'll fiddle it when the box is nearly on..
and it was pretty easy.. if anything I wonder if this was best way to do it?

Just went to change the rear diff oil.. both plugs are solid.. will try again at the weekend perhap with a long bar.. not got time to mess with it now.. weird that they use a square hole on the plugs!?

JGM

David_Wallis

its deffo easier to put the arm back in with the box on the floor put the pivot arm in and the blank back on.. bolt the gearbox up and then remember to push / pull it far engough that it clips into the clutch (i thought there was something wrong when putting the spring back on)

David

chockymonster

Looks Like I'm going to have lots of fun at the weekend!

Jolly Green Monster

iTrader: (4)

It is great fun! hummmm.....



Hope the weather holds out for you.

JGM

caz1562

Well this helps me understand a few things as I prepare to split gearbox prior to lifting the engine out.

Jay m A

iTrader: (2)

Simon

Did you fit the quickshift?

caz1562

Excellent stuff, the clutch fork pin basically fell out, thanks for the tip

Jolly Green Monster

iTrader: (4)

Caz,

No worries..

Jay,

This is an old thread brought back up..

I had a quick look when I was away the other week but had no tools.. and been in the Lakes for two weeks on holiday.
May get to do it this Friday after I have changed my headers if I get time.

Cheers

Simon

greasemonkey

Is that the £85 kit from Autospares Si, and was the release bearing included in the price?

Jolly Green Monster

iTrader: (4)

Yes and Yes. Plate, cage and release bearing..

http://www.autospares-group.com/contact.htm

In case I haven't posted it alreay.. arrived next day too

Cheers

Simon