DIY Clutch Replacement

[Schrup]

I smoked my clutch at high speed last night & don't have much pedal travel after the clutch engages (Mechanic adjusted clutch two months ago). It didn't feel like it was slipping, but stunk pretty bad. I figure I better get it fixed before my first DE on the 17th & the Rain Forest Round Up.

I ordered the Sachs power clutch kit from the host. I also called my mechanic about replacing my second gear, dog teeth, & syncros. Second gear is really becoming difficult, even on downshifts. He said I should do first gear as well even though first feels great & I can even downshift to first at 30mph if I want, although I don't.

I have a four day weekend, so my plan is on Friday to get my garage squared away. I moved in to it 2 months ago & didn't have a chance to clean & organize the way I wanted. The PO used it as a carpentry shop & there is still a lot of sawdust floating around. I am going to pull everything out, clean & vacuum, move the big 10' cabinets over to the left side wall so I can get my car in straight. Tomorrow I am going to pick up some 30" truck jackstands at Harbor Freight & Thurs a motorcycle jack from a friend.

Saturday I plan to do the engine drop with the help of some local buddies that I haven't asked as of yet. On Sunday I will remove the clutch & try & clean things up a bit. Monday I'll drop the gear box & flywheel off at the mechanics & will hopefully pick it up within a week.

I'll keep everyone posted on my progress, as this will be my first engine drop. If anyone has any tips, I sure would appreciate them. I think the only thing I'll have to find will be a flywheel lock. Are these really necessary? They don't show them in the Bentley. Any suggestions are appreciated, I will spend the next couple of days researching the Pelican archives for those little jewels that aren't in the manual. If anyone local wants to drop by, send me a pm & I'll give you my address & phone number. This is a really exciting challenge for me, the downside is the wife isn't too happy about the unexpected expense. I think I can keep the whole project under $1500. Here is some pics of my garage before I get started & I will keep all posted on how it goes.

[North Coast Cab]

Put together a good to do list as well as a thorough parts list. It's the little missing items that will delay the project. You can make a flywheel lock out of a piece of flat steel or you can buy a predrilled one at any hardware store. Only other thing to consider would be resurfacing or replacing the flywheel. There is certainly enough info in the archives to detail the drop, clutch replacement and the while your in there list. Good luck.

John

[Jay Auskin]

Like John said, you'll need a good parts list to make sure everything goes ok. Just go thru everything you have to remove, and think about if it will be re-usable or not.

Flywheel bolts, CV joint gaskets, CV bolts (if you start to round the socket heads)...that's a few which come to mind. Also, are there going to be any "while you're in there fixes"?? Crankshaft seal, leaky pressure switch, etc??

[Rot 911]

No you don't need a flywheel lock. All you need is a piece of steel strap that you can drill two holes in where you can sliide one hole over a tranny stud and the other gets bolted with one of the pressure plate bolts to the flywheel. I've even used a box end wrench once.

[vash]

flywheel lock? no way, i helped a friend and he used a strap of metal from home depot. i think the original purpose is one of those carpentry straps from simpson strongtie. it even had a bunch of holes predrilled along the center. betcha can find a good strap in one of those cabinets!
nice garage btw. good luck, sounds like a good weekend. fix any leaks and if your sound pad looks like crap, this is as good a time as any.

[H20911]

......plastic clutch alighnment tool. If you dont have one local auto parts stores can match them up just bring the old clutch and pilot size.

[yelcab1]

Fly wheel lock? Do you have a box end wrench? That will do.

1. Use a bolt to screw the end into the flywheel bolt holes
2. Slip the open end over one of the long engine/tranny studs.

THere is your fly wheel lock.

[Scooter]

I guess this means you won't be joining us for the Quelle911 run this weekend. Good luck with your project.

[andyu911]

How about a furniture dolly for your engine drop? 2 jack pads with 2 jacks?
BTW, I like your garage with all the windows up there? You have a picture of the exterior?

[k9handler]

take your time, start on the interior with the shifter coupler (so you don't forget) and if possible follow Waynes book as it'a pretty accurate reguardless the engine model. Take your time and lable all the connections so you know where to reconnect them...pics of everything will also help (before and after). Have fun!

[Schrup]

Thanks for the input so far. I'll just make my own flywheel lock. My mechanic is getting my flywheel resurfaced. I'll ask him to order me a new crankshaft seal & any other seals that he thinks I might need. The alignment tool comes with the kit I'm buying from Wayne. My CV joints are only a few months old so I'll just inspect the bolts & wrap everything up in plastic & wire it under the car. I can't seem to find my 101 projects after my move so I may have to get by with the Bentley.

My rear valence is already removed, so I figure I'll remove my bumper for some added space. I'm starting to think that I won't need the truck jack stands & that the 2 ton stands I have will work fine. Besides Harbor Freight is only a mile away. I only have one jack & jack pad, so I'll probable find another jack to borrow & have my friend weld me up another pad. Thursday I'll buy the wheels to make a 3 sided dolly to fit around the ATV jack.

Andy, this is the best pic I have of my garage right now, it is separated by a breeze way from the house.

[ChrisBennet]

You don't even need a flywheel lock, just put it in 2 gears at once.
-Chris
EDIT: I don't know what I was thinking! I had my mind on the the transmission.

[Rick Lee]

If you want to make it a fast engine drop, use two floor jacks. Amazing how much time you save by jacking up the left and right sides at the same time. In NoVA land we use a Costco or Craftsman motorcycle jack with a modified pallet to lower the engine from the car. I hope you plan on doing a valve adj. while you're in there. You should have it all done in two weekends. Keep John Walker's number programmed in your cell phone. We even do that here in NoVA.

[Superman]

Sorry I did not call you last night. Count me in for help, although I won't have a ton of time. Perhaps I could come by about the time the drop is to occur. I think you're familiar with plumbers' tape, which would make a good flywheel lock but I also have a real flywheel lock. Tyson's, actually. And I have a jacking pad, and floor jack, and a pair of 3-ton jackstands and a pair of smaller jackstands. And a furniture dolly. If you get things unhooked, this will be faster and easier than you think.

You'll need an oil cooler thermostat o-ring and a new oil pressure switch. There are some hoses back there that might be old and thin or brittle. Many folks replace intake runner hose pieces at this time. Six of those. I also have an engine stand, but I do not have the special yoke.

[andyu911]

Nice house, Paul.
Last time I dropped mine, I did what Superman said plus the breather hose and the gasket. They are hard to reach with the engine in the car.
Have fun with your project!

[brcorp]

While the engine is out do a valve adjustment.

[juanbenae]

is that house an Ickler (sp? Ike-ler as pronounced)? i thought those places were only here in california? does it have the in slab floor heating? nice looking place by the way

[H20911]

also with the alignment tool on the clutch disc....make sure that you are pushing firmly towards the engine with it as you tighten the pressure plate bolts in a 3 point pattern (this will lift the disc slightly but align it).
If you do not the clutch disc will droop behind the pressure plate and not be aligned perfectly.
this will make the trans harder to get back on.....and that sux