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Not that it's a huge task, but mine had its pitfalls. As I had previously posted stating I couldn't get the clutch shaft out, things started to progress once I got passed that point.
A few things to mention.
I used an old spark plug wire cut to fit as the spacer tool to keep the fingers of the pressure plate away from the slave cylinder.
For installing the rear main seal (behin the flywheel), I used the method of a 4" pvc pipe end cap. I found one that did not have any threads (it was also not pvc but some other harder plastic). I did have to drill the holes in it to line up to the holes in the crankshaft in order to use the flywheel bolts for pressing the seal in. You've also got to drill out a hole in the center to fit over the center lip of the crankshaft. I used old poly endlink bushings (from my 9000) as the spacer between the cap and the bolt, to keep the cap from cracking. The seal went in, but not as far as I would have liked it. It's supposed to go in 1/16" further than where the old one was, but I think the new one went in that much less than before. I don't see any leaks, so I hope it holds. Definitely lube the inner lip on that seal with motor oil to allow it to ease onto the crankshaft.
I did not use any sealer on the outer edge of the RMS, pilot bearing, or clutch shaft seal.
I used a socket and hammer to r&r the pilot bearing, the same size as the outer race. Worked like a charm!
I lubed the clutch shaft splines (both sets of splines) with silver anti-seize lube. I also lubed the clutch shaft seal inner lip with cv-joint grease (just a little).
I had a hard time finding 518 anaerobic sealant for the flywheel and slave cylinder bolts. It seems Permatex Thread Sealer is the same thing, so I used it (that cross-checked with the 518).
To lock the flywheel, I jammed a cold chisel down between the teeth of the flywheel and the bottom casing of the tranny. I had to hold the chisel in that position with one hand, and then tighten and torque the flywheel and pressure plate bolts with the other hand. I cleaned both faces of the pp and flywheel with brake cleaner until the rag came away clean.
I bled the clutch hydraulic system with the method of attaching a clear tube to the bleeder nipple on the slave, filling it with brake fluid, cracking open the nipple slightly, then blowing into the tube to send the fluid into the system backwards. Just be sure to watch the amount of fluid in the tube as well as in the brake master cylinder. Never let either run out or you'll send air into the system. I eventually had to bleed the system the normal way since some air bubbles were present in the line. I did this by pressing up and down on the clutch pedal a few times (bleeder nipple closed), then holding the pedal down while I cracked open the bleeder nipple. Air popped out, then fluid came out. Close the bleeder and repeat process until only fluid runs out (no air). Be sure to keep the brake master cylinder topped off with fluid.
After wrestling with the clutch cover for what seemed like hours, I found the way mine went in. The top portion needs to go in first, then lift it up as much as possible to get the bottom part in, but working on the driver's side first (to get the cover in and under the fluid lines). Once it's in this position, the other side of it basically pops in (with a little force).
Clutch is like butter now. It was fine before (the release bearing was shot, but the pp and disc looked fairly new, as though only those parts had been replaced by the PO), but it's even better now. I also replaced the front engine mount and did the movement-limit mod on it, so that might also play into this new, smooth feeling.
I noticed the spring was missing that is inside the accordion-looking boot on the slave cylinder, as well as the plastic propeller screw on the end of the clutch shaft. Whoever did the last clutch job definitely did not pay attention.
Expect to spend a few hours to a full-day doing this job. Mine took 2 weekends since I only had a few hours each time, and I had been away on vacation for one week in the middle. I also had some problems along the way, slowing down the process.
Things I replaced:
Rear main seal
Pilot bearing
Clutch disc
Release bearing
Slave cylinder
Clutch shaft seal
Shaft cover seal
Front motor mount (not needed for a clutch job, though)
I did not replace the pressure plate or have the flywheel resurfaced. Both pieces were in perfect condition.
Thanks for everyone's help!!! I used all of your tips!!!
Joe
'93 900TC 147K
'98 9000CSET 96K
posted by 12.111....
, Tue, 25 Apr 2006 12:25:30, Tue, 25 Apr 2006 13:51:30
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