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clutch replacement tips/woes (long!)
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Posted by pete [Email] (#2000) [Profile/Gallery] (more from pete) on Sun, 29 Apr 2007 13:55:39 Share Post by Email
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Here's some more tips I have gleaned from doing my hydraulic clutch upgrade (& clutch replacement). Platonoff's guide for the manual transmission is excellent. However, if you are installing the hydraulic clutch upgrade, the photo for the clip insertion for the bleed nipple assembly on the transmission bell housing is slightly incorrect (thanks to BUCK on the BB for putting me right). If you are looking at the picture for inserting the spring clip to fastening the bleed nipple assembly to the nipple protruding from the bell housing, firstly: the clip can be installed on the bleed nipple housing BEFORE snapping the bleed nipple housing onto the nipple on the bell housing. This will ensure that the bleed nipple assembly is fastened snugly on the bell housing nipple. Secondly, the spring clip does not insert into the small cutaway in the bleed nipple assembly. Rather, the spring clip inserts into the two horizontal slots cut into the side of the bleed nipple assembly ... so the clip spans the two slots with just the head of the clip visible between the two slots. (so if you are trying to insert it into the small hole, you're doing it wrong ... like I tried for several frustrating hours).

After getting the tranny on and bleeding the system, I was all ready to get the subframe on and finish up. ... then I noticed "the drip" of hydraulic fluid from the bottom of the bellhousing. So I backed off the tranny just far enough to peak inside to see where the drip was coming from; the screw in connection on the slave cylinder or the %^&**$ bellhousing/bleed nipple assembly. Sure enough, the drip was from the latter. So I reseated the bh/bna with the clip in place before snapping it on the bellhouse nipple (as per point above). Went on nice and snug this time. So to check the system for leaks before pushing the tranny on, I bled the system and pushed the clutch pedal in a few times.

Yeah, don't do this at home kids.

I destroyed the new clutch slave. It didn't like being pressurized without anything to push against (i.e. the clutch pressure plate).

Ah well, it was an expensive lesson.. but I hope this helps someone. Now to ply the wife with gifts, whose '99 9-3 I've been driving for the past few weeks while I do all the upgrades....

Think I'll go back to riding my bike in future....
Sigh.
Pete


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