15 replies to this topic

[LukeFranky]

Hi everyone,

 

The issues with my B4 don't seem to end.

 

As you may know a while ago I replaced my clutch and gearbox. This week the clutch started slipping. The clutch kit is an Exedy HD Cushion Button: FJK-7123HDCB.

 

The flywheel was machined, real main seal and spigot bearing replaced. Only thing I didn't do was the clutch fork because it looked alright. I had a mechanic help me with the install (actually, I helped him).

 

Ever since day one the clutch had a shudder, same shudder that was there on the old clutch actually. I suspected engine mounts.

 

About a month ago was the first sign of trouble. I had issues getting into gear. Readjusted the clutch from under the dash and all was good again.

 

This week it started slipping. First thing I tried was readjusting it under the dash again. No matter how much play I give it the clutch still slips under load.

 

I'm at a loss. The clutch has been holding well until now. Any ideas?

 

One other thing worth noting: Before I had to replace the old clutch the hose between the master and slave cylinders split. I had a mob in town make me a new hose. They did a pretty good job of it. Looked identical. I highly doubt this would be related.

 

Thanks,

[LukeFranky]

Pulled the intercooler off. Looks to be internal.

https://www.dropbox....174355.mp4?dl=0

Any ideas what it could be?

[natho]

oil or grease on the clutch.

[duncanm]

did that split line leak brake fluid into the bellhousing?

[LukeFranky]

did that split line leak brake fluid into the bellhousing?

- Doubt it.

 

 

So after work I got busy and ripped the box off. You won't believe what I discovered...

 

The bolts holding the clutch cover to the fly wheel had come loose! Most of them I can undo with my fingers. Not sure how that could happen. We're fairly positive we torqued them up.

 

I'm yet to totally pull the clutch out. I'll do that this afternoon and inspect it and the fly wheel. Hoping to just put it back together with some thread locker and pretend this never happened.

 

 

 20160310_211933.jpg   113.48KB   7 downloads

[LukeFranky]

The clutch and flywheel are stuffed.

I'm looking for something that will be reliable. Maybe a lightened flywheel. Any suggestions?

[natho]

damn you're having bad luck... what's wrong with them?

 

fair few kits out there, i know of people using the exedy ones.

[duncanm]

standard clutch, standard flywheel.

Why go for anything silly ? You'll just break the box.

[Jimbo]

Pro tip ;

When torquing up bolts, put a bit of oil or grease onto the threads. If you do it dry, the torque wrench can click out early if there's too much friction and you wont get your desired torque.

If you lube them up a bit you get your desired torque without friction causing interference. 

[cowie165]

Pro tip ;

When torquing up bolts, put a bit of oil or grease onto the threads. If you do it dry, the torque wrench can click out early if there's too much friction and you wont get your desired torque.

If you lube them up a bit you get your desired torque without friction causing interference. 

 

What grease would you use? Would you think it's too hot for copper grease?

[LukeFranky]

As a result of the loose clutch cover the clutch disc has chewed on itself, the pressure plate and flywheel.

There was a groove on one side of the fly but I've been told it can still be machined out.

Has anyone ever had a pressure plate machined? I'm considering it as an option because it is possible to buy a clutch disc on its own.

[Jimbo]

 

What grease would you use? Would you think it's too hot for copper grease?

You can use just oil or any lubricant really. Mate of mine works for MTU Detroit Diesel and is an engineer and has so many tips and tricks. Stuff I wouldn't have even thought of!

[LukeFranky]

Bought and installed a HD Exedy kit. This one isn't cushion button though.

Flywheel got machined. Apparently it took them over an hour to get flat.

Shudder has all but disappeared. Car drives much better. Cost roughly $600 total and over day and half of work on my back.

Once I got the clutch worn in I did a launch at 3000 rpm. Tires weren't too hot but I never realised how much torque the beast has at such low rpm. Spun the wheels for a few moments
...in the dry! Won't try that again incase I break the box.

[Jimbo]

Another success story!

Looks like there's a run of luck in the club lately!

So is the whole thing good as gold now?

Any more issues or is she happy?

[LukeFranky]

She's pretty happy but knowing me I will continue to work on something. Always something next on list, but mostly minor now.

 

Went away for easter and she cruised beautifully. Really have to watch my speed on the highway. Breath on the throttle a little too hard and will be 20km over the limit in no time at all. Installing after market cruise control crossed my mind.

 

With the A/F issues sorted the VOD is barely noticeable. Overtaking is so effortless. Drop a gear or two, plant it and I'm past them in seconds. I'm falling in love all over again. There's something special about the twins.

[Jimbo]

There is indeed!

All the hard work, sweat, tears and copious amounts of swearing and throwing of tools, pays off in the end.