Clutch issue, think I know what it is.......

Hi DeeJay,
I have discounted existing parts seeing the clutch worked fine prior to removal of the engine. Overhauled the engine used the original flywheel. I have changed nothing apart from the pressure plate, friction plate, release bearing and spigot bearing. I had the really smart idea to replace the fluid in the clutch system whilst the engine was out and I think this is where my issues started, however I no longer belie the problem is with the slave or master cylinder.

Hi Dave,
Aren't you just full of the "joys of spring", no pun intended. Well at least you have now given me a reasonable explanation to take the gearbox out and check things, and no doubt put right. Gee whizzer this is frustrating and everything was going so well. could you just define which plates you are talking about in this sentence "the plate engages on a part of the plate and deforms the friction plate", got the friction plate bit I am assuming that one plate referenced could be the pressure plate, is the other plate referenced the flywheel?

The thread referenced by Kyle mentioned that the large collar faces the flywheel, whereas by your description I get the feeling that it is the additional contact with the flywheel on the friction plate that gives me the problem.

I know I have to take the gearbox out so the problem will resolve itself shortly and I will know by looking at the friction plate which is right and which is wrong, I have obviously installed the friction plate the wrong way around.

Thanks again Chaps

Marty

Cheers Marty.

I know of a clutch plate that got stuck to the flywheel due to excess loctite on the pressure plate bolts running down behind the friction plate.
Have you tried cranking it on the starter while in gear with the clutch depressed? Might clarify if it's just dragging or completely solid.

Steve

Hi Steve,
That's a good one, I don't believe that this is my problem I can start the engine with her in gear and the clutch depressed, the engine is straining however running, if I release the clutch the engine stalls, usually after I have lifted the pedal maybe 50 mm from the hard down position. If I depress the clutch with the engine running I can't get a gear even in low range.

I would not have picked that one, to much Loctite, wouldn't credit it...... its amazing what you can achieve when you put your mind to it.

Cheers Marty

it sure sounds like something is wrong inside the pressure plate. I would be removing the clutch to have a look and rectify the problem.
After checking which way round the clutch plate is i would check the clutch bearing and make sure it is the same as the old one.
I have heard of damage occuring to pressure plates and clutch plates if the bolts are not tightened up evenly and too much load is put onto one side of the new pressure plate.
The new pressure plate or clutch plate could also be faulty or the wrong size. Lots of checking needs to be done.

Good Luck

Ian
Bittern

Hi Ian,
I have been caught before and this is part of the frustration, I measured everything to ensure that all the parts I was fitting were dimensionally the same, I didn't really want to end up where I am right now. I'm off work tomorrow and Friday so I'm hoping I get onto this tomorrow, I'll take some pix of the findings when I get in there.

Great suggestions thank you, everyone has been so helpful. taking the box out this time and not the engine gives me access to replace the transfer case / gearbox oil seals and replace that o-ring in the intermediate shaft.

I'll be in touch,
Cheers Marty

....or you could go down the olde commonly suggested "AULRO Solution" since you are half way there. You have got Diseasel, now all you want is a box of Bryant & Mays.

I know, I know, not helping am I?[biggrin]

Well this wasn't the first option that flashed through my head, however prepared to listen to all options and consider them on their own merits. My dad was more of a Swan Vestas man, personally when I smoked and gave up about 30 years ago a lighter was the preferred option...….. and yes they did have lighters then...…….. [thumbsupbig][thumbsupbig]

Cheers Marty

The world has moved on since then. Barbecue Blocks & Heat Beads & Butane is the go now. [biggrin]

Quote:

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Originally Posted by Nomad9

Hi DeeJay,
could you just define which plates you are talking about in this sentence "the plate engages on a part of the plate and deforms the friction plate", got the friction plate bit I am assuming that one plate referenced could be the pressure plate, is the other plate referenced the flywheel?
Cheers Marty.

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the intereferance is between the friction plate and the pressure plate.

Hi There,
Removed transfer box yesterday gearbox today. I can confirm that I fitted the friction plate the wrong way round. The large hub of the friction plate faces the FLYWHEEL, NOT the pressure plate (as I had it).

When I got the trusty Vernier out and used the gearbox flange and the back of the engine as the datum what actually binds up is the splines on the friction plate and the mainshaft of the gearbox. This loads up the centre of the friction plate onto the flywheel. The inner say 5 to 10 mm of the flywheel surface was highly polished and there was evidence of heat and a whisker of friction plate dust on the friction plate. Everything now cleaned up and reassembled.

Going to give the gearbox and transfer case a good clean down I'll put them back next weekend. Just glad I found the problem and no damage done. So easily could have overloaded the thrust in the gearbox and screed that up as well, all that side of thing appears fine.

Thanks for all the hints and tips along the way. I have included a couple of pictures, first one is the friction plate installed INCORRECTLY and the second picture is showing some grubby stuff at the end of the spline nearest the gearbox which further confirms what the problem was.

Attachment 153399Attachment 153400

Cheers Marty