As I may have mentioned before the clutch release bearing as always been noisy since I bought the car. This could be the route cause of the clutch ratchet problem I was having. The clutch itself is fine but after seeing what happened to Johnc172's cup clutch on track I thought it wise to change it now before it lunched itself.
As im sure we are all aware its quite a big job. So with the help of a mate we got started. To make access easier we took off the bumper.
Coz that was off I took the chance to change the drivers side wing as mine was broken on the bumper fixing point. Im also after a new bumper to tidy the car up a little more.
Found a s**t load of dirt trapped behind the wing, 9 years worth.
Resisted the urge to sweep it all up and weigh it
I will be cleaning the nearside too tho :approve:
So onto the clutch change, first job was to remove the hubs and driveshafts. The trackrod end on the drivers side gave us some trouble, so we got medievil on it.
Big hammers and pigs trotter tool and 30mins later it was off. Passenger side must of seen what was going on and gave up without a fight. Two new ones when rebuilding tho I think.
Took off the calipers and seriously well used DS2500's. The discs are ruined also, so more to add to the shopping list.
Drained the gearbox, oil was very clean but then its only been in there for a few thousand miles.
Lower ball joint bolts off and shaft pulled out of the box. Whole assembly put to one side.
Same on the passenger side but it has 3 bolts holding the shaft in.
Took off the gearbox 'dogbone'
Undone the subframe strengthening bits (not sure on their real name) The bolts to the subframe didn't want to come out so got left on and just undone from the chassis. Will try and free the rusted bolts before it goes back in.
After undoing the gear linkage, a couple of pipes and wires that were in the way, the front gearbox support, the pas pipe where its bolted to the block and supporting the radiator from above, we used two trolley jacks to lower the subframe down slowly, making sure nothing was catching.
Not that hard to do tbh, just a lot to take off and a bit tight with the pas pipes. Safe to say I wont be cleaning and painting the subframe. It wont go back in until we have fitted the new brake pipes as access is a doddle now. Also I need to loosen the support bolts that were seized and change some bits on the rack.
We carried on and got the gearbox out.......
Supported the engine.
Gearbox mount and bell housing bolts out, lowered the engine down a little and lifted the box out.
To find a pleasent sight, the clutch cover very badly worn by the breaing. Not much longer and the release bearing would of gone through the cover.
Took the brearing out and that was very notchy and partly seized.
The actual friction plate was in very good nick. the cover has probably worn like that due to someone sitting in traffic with their foot on the clutch all the time, instead of using neutral and the handbrake. Should be very nice to drive now with a new one in.
Picked a replacement up off the forum a while ago. Borg and Beck, apparently uprated slightly.
Gave the bellhousing a wash out and lubricated the pivot.
Now at this point I considered removing the flywheel and sending it off for a skim and ballance. I would of had to put the box back in temprary so the engine could be supported (I couldnt leave it on the jack) I made a phone call to my local machine shop who said they could do the work for me but it could be a week or so as they had to send it to another company for ballancing. They could of skimmed it and had it back to me within a day tho. As I wont have much time to spend on the car for a few weeks i made the decision (after a long chat with a work mate) to just put it back together as it was. the flywheel didnt 'need' a skim as the face was very clean and I hadnt had any judder at all. The only problem was the cover and bearing. Lightening the flywheel would of been nice but it was a time and cost factor.
Box went back in..........
One major job done and a step closer to the end. time is going to be more difficult to find over the next few weeks so im happy this is done.
