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Thread: Clutch failure within a few days of being installed (Holden 202 engine)

  1. #21
    Join Date
    May 2007
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    Denmark WA
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    How’s it going? This is getting to be like a series that gets dropped at the end of the first one which was leading to a critical question being answered! Save me from the anxiety of waiting!
    1974 Military Lightweight Landy --- Some dementia at 48 years old
    2000 Disco series 2 now sadly moved on!
    No5 Trailer joined the fold... Awaiting graduation to road licensed!
    Ford Ranger 2013 XLT.

  2. #22
    Join Date
    Sep 2015
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    Sydney
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    I do apologise for disapearing on this! Been a very crazy few months so I didn't get back to where the car is stored to continue working on it for a while... It seems that there were two problems...

    The first: As Sharmy suggested, the clutch slave cylinder was broken, with the fluid not returning to the line or something like this, I tested by releasing the pressure from the bleed nipple, the clutch then seemed to work again once or twice before not disengaging again. I replaced the slave cylinder and it was working again!

    The second issue, and quite possibly the root cause of the first is that I had, very stupidly, installed the wrong clutch unit, I installed the Holden red 202 clutch but when I went back and checked the old one it was clearly a Series clutch (with the boss in the middle). So when I re-attached the gearbox the clutch was still not 100% disengaging, i believe because of the different throw distance required...

    I ordered a 9.5" clutch from paddocks that SEEMED like it would match from the pictures etc, but that doesnt line up with the holes when comparing it to the old one. I am at a bit of a loss here, from what i can see from the photos online, the 9.5" clutch (and the diesal which i think is also 9.5") is the type with the boss in the middle for the clutch release bearing, which is similar in appearance to what I pulled out of the car at the beggining of the restoration. The 9" petrol version appears to have 3 'arms' rather than the conventional many arms that point to the centre (pressure plate). Because this is bit of a mismatch car (series 2a, Holden engine, Series 3 gearbox) I am completely lost on what is the right clutch to buy...

    Clutch_Units.jpg

  3. #23
    Join Date
    Apr 2019
    Location
    Medowie
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    I think it is the gearbox that dictates what clutch is required, unless other changes have been made (such as the bell housing). This would mean a Series 3 clutch is required for a unadulterated Series 3 box, which is neither of the options you have photographed (both are Series 2a clutches). Cheers, Matt

    Quote Originally Posted by Harro_9 View Post
    I do apologise for disapearing on this! Been a very crazy few months so I didn't get back to where the car is stored to continue working on it for a while... It seems that there were two problems...

    The first: As Sharmy suggested, the clutch slave cylinder was broken, with the fluid not returning to the line or something like this, I tested by releasing the pressure from the bleed nipple, the clutch then seemed to work again once or twice before not disengaging again. I replaced the slave cylinder and it was working again!

    The second issue, and quite possibly the root cause of the first is that I had, very stupidly, installed the wrong clutch unit, I installed the Holden red 202 clutch but when I went back and checked the old one it was clearly a Series clutch (with the boss in the middle). So when I re-attached the gearbox the clutch was still not 100% disengaging, i believe because of the different throw distance required...

    I ordered a 9.5" clutch from paddocks that SEEMED like it would match from the pictures etc, but that doesnt line up with the holes when comparing it to the old one. I am at a bit of a loss here, from what i can see from the photos online, the 9.5" clutch (and the diesal which i think is also 9.5") is the type with the boss in the middle for the clutch release bearing, which is similar in appearance to what I pulled out of the car at the beggining of the restoration. The 9" petrol version appears to have 3 'arms' rather than the conventional many arms that point to the centre (pressure plate). Because this is bit of a mismatch car (series 2a, Holden engine, Series 3 gearbox) I am completely lost on what is the right clutch to buy...

    Clutch_Units.jpg

  4. #24
    Join Date
    Sep 2015
    Location
    Sydney
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    Quote Originally Posted by drfish View Post
    I think it is the gearbox that dictates what clutch is required, unless other changes have been made (such as the bell housing). This would mean a Series 3 clutch is required for a unadulterated Series 3 box, which is neither of the options you have photographed (both are Series 2a clutches). Cheers, Matt
    Sorry I should have mentioned, the bell housing has also been modified in order to attached to the Holden engine. The flywheel has threaded holes both for a Holden clutch (somehwat how I made that mistake) and additional holes for a land rover clutch. In the pictures I have seen the series 3 clutch does not seem to have the boss in the middle of the diaphram which makes me think it isnt a series 3 clutch I need.

    Thanks,
    Luke

  5. #25
    Join Date
    Apr 2019
    Location
    Medowie
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    Do you mean the flywheel housing is modified, rather than the bell housing - the flywheel housing is the part that does the “adapting” between a Holden engine and a Series gearbox. I pulled a 186 off a Series 3 gearbox (formerly 2.25P) last week and it was definitely a Series 3 clutch plate, with no boss

    Quote Originally Posted by Harro_9 View Post
    Sorry I should have mentioned, the bell housing has also been modified in order to attached to the Holden engine. The flywheel has threaded holes both for a Holden clutch (somehwat how I made that mistake) and additional holes for a land rover clutch. In the pictures I have seen the series 3 clutch does not seem to have the boss in the middle of the diaphram which makes me think it isnt a series 3 clutch I need.

    Thanks,
    Luke

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