warning - issue on clutch R&R and speed sensor clearnance
 

Clarke's garage has great write ups for replacing the clutch as well as setting the clearance for the speed/crank sensors.

but I have stumbled on a couple issues for both, and have sent him an email with this info.

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during my clutch job, as I was pulling the bell housing I just could not figure out how to get to and remove the top bolt and bolt for the ground to the bell housing. they are hiding under the heater control valve / hose.

after struggling for a while, finally pulled the HCV hose from the block. when I did some coolant drained, and thought I had tilted it down to drain out any remaining coolant.

pushed it up and to the side and got both bolts out.

ironically, as I was installing the new clutch and the bell housing, there is a note in the Clarke's garage 'installation' section of the procedure that you will need to pull the HCV/hose off the block to get to these bolts.

in the procedure it cautions to put tape over the TDC inspection hole to avoid dropping bolts, washers, or other bits down inside the bell housing.

after getting all the bolts in from below, went up top to install that bolt and the ground.

I stuffed some paper towel into the TDC hole and begin to install the bolts. in the process I moved the HCV and some coolant poured right down into the TDC hole. went right through the paper towel.

pulled the clutch back out and sure enough, some of the clutch disc material was contaminated. sent back to SPEC to resurface.

so COVER THAT DAMN HOLE GOOD.

what I am thinking of doing when I do put the bell housing back on is use some aluminum duct tape and cover the hole. don't want to risk dumping coolant in there again. and just leave in place until I do something to need to set/verify TDC as that kind of tape should be able to take the heat. that would eliminate risk of dropping anything down there when doing any other work. in the past I either stuffed some paper towel in or covered with some blue painter tape. the painter tape may have saved me.

this could also happen if you replace the HCV. I am glad I had not reinstalled the TT and trans.:eek:

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when I pulled out both sensors to remove the bell housing, noticed some very slight, superficial scratching on the speed sensor. during the build I had replaced both and used the 0.8mm washer technique to reset the clearance.

I put in a new SPEC clutch, PP, and alum flywheel. due to that, needed to set the clearance on that crank sensor pin.

but now with the bell housing off, could see there was almost no clearance between the speed sensor and the starter ring teeth.

initially figured I had just messed up setting the clearance before. so using a real feeler gauge, adjusted the bracket so the clearance for the speed sensor was correct from below.

in the process I realize what MAY have happened. but just suspicion.

when gluing the 0.8 mm thick washer to the sensor, the hole in the center area can allow it to sit down with the teeth landing inside the hole and the 0.8mm landing between the teeth. so you end up with basically no clearance between the sensor and the teeth.

in the future should I need to set this clearance, I will use a solid piece 0.8mm thick to ensure I will get the correct clearance.

pic of the sensor/washer I had used, very similar to that shown in Clarke's garage.

http://forums.pelicanparts.com/uploa...1422644241.jpg

Good tips, thanks for posting :).

well..... have to eat some crow.

as I was installing the new clutch, decided to check out my speed senor clearance theory.

FAIL

here is a pic I took of the sensor with washer against the starter ring. the ring gear is wide enough that the teeth cannot fit into the washer gap.

so I must have set the clearance wrong. when setting with a feeler gauge with the bell housing off, had to try a couple times to keep the clearance were I wanted as I tightened the bracket bolts. hard to tell using the washer method if you put downward pressure on the bracket which may reduce the clearance from what you intended.


http://forums.pelicanparts.com/uploa...1423407066.jpg

now for that damn hole ..... the hole I covered on the left is for that obsolete diagnostic sensor I removed.
http://forums.pelicanparts.com/uploa...1423407101.jpg

You're fired.




;).

ROFLMAO.....

I deserve being fired.

not sure I want to post about yet another mistake I made and just discovered about setting clearance on these sensors in time to fix before I button up the bell housing. but probably should. need to finish sorting out how I messed it up before I do.

watching the TODAY show and they had Steve Harvey on. they asked how he developed the knowledge to provide such good advice on his show as he does not have any formal psychology training.

his reply was something like "making a lot of mistakes in life is a great teacher".

Dave Lindsey teased me about how good I will be on 951s when done with this build. having to figure out stuff or unravel my mistakes have taught me a lot. I really hope I don't have to learn as much the same way when I really get into the build of my 930.

I really appreciate all the post folks have made of their fubars. I only hope my posts of my mistakes will help someone else avoid the time and expense mine cost me.

OK another confession of a noob wrench.
 

so installing the new clutch and alum flywheel.

first adjusted the bracket to set the clearance on the speed sensor to the starter ring.

then adjust the pin on the new flywheel to the correct clearance on the crank sensor.

well....

as I was trying to put on the bell housing for what would have been the final fitting, it would not go. finally figured out the flywheel pin was set way too long and it would not clear the bell housing.

when putting in the sensors to set the clearance, I got them mixed. so with the washer on the crank sensor now on the hole for the speed sensor I actually set the bracket way to high.

what I suspected as the delta appeared to be exactly twice the thickness of that washer. but just finished looking at PET and the WSM ... AGAIN ... to confirm my bone head move. Ironically, I had actually looked it up in the WSM at the time, but still went and put them in reversed.

initially I had been able to put on the bell housing, as the pin was still up around the sensors. glad I had pulled it back off and turned the pin down to remove the tape I put on to hold while the loctite set.

so heed the warning to have the FLYWHEEL PIN FACING STRAIGHT DOWN when you put on the bell housing. when I saw that note in the procedure, I thought 'why'. now I know. that way you will know if it is too long. the lower area of the bell house has the least clearance to the flywheel.

I just cringe at the thought of having buttoned it all up with that pin too long. hit the starter and no telling what noise and damage the impact of the pin on the bell housing would have caused.

once again, hope to save someone else from making the same mistakes I have.



http://forums.pelicanparts.com/uploa...1423508406.jpg

dang ... I cant even write a correction to a post correctly. :(

the correct comment is, "WITHOUT the washer on the speed sensor".