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DIY clutch--- success, but it was a challenge(!) (long) Posted by kenS [Email]  (#606) [Profile/Gallery]
(more from kenS) on Sun, 8 Jan 2006 14:28:58
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Thought I would share my experiences on a 1st time clutch DIY--- '87 900T, 178K, original clutch + slave + seals, needless to say, it was past due for a r&r. I decided to go for better performance, so Dave Kennedy at Lesco provided me with a 9000-AP type, plus a much- lightened flywheel (only 14 lbs!), fully balanced. I read everything I could on this board, then started in. Everything went smoothly, except for: (1) the clutch shaft seal--- when I tried to pry it out, it immediately broke into pieces, then took me HOURS to get the rest out without mangling the housing. I finally managed to get it with a hook-type seal remover, leveraging against the other side of the seal. I even had a time placing the new one, there just isn't much room in there to tap it in; (2) then after I had everything back together, I committed the beginner's sin of overextending the slave while trying to remove the spacer wire. The slave cylinder popped out past it's o-ring, hydraulic fluid started leaking everwhere, and the entire assembly was jammed tightly in place. I started to reach for a hacksaw, then decided to take a break and think about it. I realized I could probably push the slave cylinder back in, so I undid the 3 allen bolts, then managed to get a thin pry bar behind the slave body, and carefully pushed the cylinder back in. I took everything out, put a new o-ring/seal in the slave, then re-assembled it. This time I got my wife to sit in the car and carefully push on the pedal while I wiggled the spacer wire free. Much to my surprise, everything worked fine on a short test drive! Pedal action is way smoother, less effort. Clutch works great, no slipping. And, the lightened flywheel feels a bit different--- revs drop & build a bit faster, but no problems w/ stalling, etc.
The whole job took me about 2-3x official shop time (I think official time is 5 or 6 hrs?). In addition to the spacer wire, I also had access to 3 special tools--- the rear seal tool (8392540), a flywheel lock tool (8392987, and the "holder" (8792020)--- this is a stamped metal double fork that compresses and holds the rubber bellows and release bearing together. It makes sliding the slave + bearing + clutch in place a whole lot easier, especially if you are working alone.
All in all a successful weekend, although I think I will keep my day job...
posted by 24.6.21...
, Sun, 8 Jan 2006 14:28:58 <-- Viewing This Message
, Sun, 8 Jan 2006 16:37:55, Sun, 8 Jan 2006 17:30:59
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