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Thread: Clutch job over next few days (again!!!)

  1. #1
    adaxo's Avatar

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    Clutch job over next few days (again!!!)

    Just got delivered new clutch and input shaft bearing for a Legnum, I will start to change this tomorrow but (as usual) got few doubts/questions,

    - I probably will need to have flywheel skimmed, anyone know where in Manchester area this could be done properly?? and it has to be rebalanced after??

    - How long new clutch need to be driven to bed in??, bog standard evo Exedy kit no MBK2084

    - I read the procedure how to shimming the bearings in gbox but if anybody got any hints, tips or anything to add how to do this properly, please say now, any advice will be appreciated and may I could do some pictures of the process for future reference. (cant find any evo gbox ones in the net)


    that's it for now, thanks for any inputs.
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    adaxo's Avatar

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    Thanks , but I take the gbox out b4 so I'm pretty confident in knowledge how to take this out and put back in, , so far only this three things mentioned above not let me to have a proper peaceful sleep over this night.

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    Davezj's Avatar

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    Adam do you want that motor bike jack, I can drop it round tonight if you want.
    It is no problem.

    Bye for Now!

  5. #5
    adaxo's Avatar

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    Thanks Dave, I think, I can manage without this jack and what's worrying me is that your jack its fairly big, so I could struggle with space for all bits from under bonnet plus all my jacks and tools, you know how tiny is my garage or should I say, how its cluttered with all sorts of mostly crap?

    anyway, if you get boring, you can still come and have a tea or something, cheers

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    Davezj's Avatar

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    Thank for the offer, but I have to pass as I am up at 6.00am in the morning.

    I will ask about the LPG in a different thread.

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    Nick Mann's Avatar

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    Sorry, I'd love to help but it is something I haven't done yet. Where is the re-assembly write up?

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    adaxo's Avatar

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    Here http://www.evoscan.com/manuals/Evo9/GR00000500-22B.pdf , page 22B-10 is what looks pretty straight forward, (at last in theory)

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    Think new clutches take 800-1000km to be properly bedded in

  10. #10
    adaxo's Avatar

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    Ok, time for a small update.

    Car is eventually put together after all that time and I think is worth to share what you can expect when try to fix manual gearbox properly. All info below is only MY way and is not by any means approved by MMC.

    Clutch kit what I chose is completely bog standard evo 7,8,9 exedy MBK2084, bought here
    gbox 001 (Medium).JPGgbox 004 (Medium).JPG

    The reason why I pick this clutch was mainly that I drive my vr4 on daily basis around Manchester and drive a 'civil' car on 4 puk pro shop lida clutch was PITA, manage slow traffic speed was unbearable and judger was unreal (at least by my standards), so after much swearing and complains made by my miss I decide to go standard and WHAT A CHANGE!!! I cant remember (since manual conversion) to enjoy drive vr4 like I do now, its transform a car completely from harsh/judder/clunking POS to 'like new car' felling.
    So far I've done 100 miles so cant say anything how that clutch manage torque at WOT but hope it will last for few thousand miles.

    OK, lets back to the gbox shimming, I read about that process on various forums (mlr, evo123, youtube etc) but cant find any pictures of the exact process so here we go:

    first of all you need to split the gbox (obviously), very easy (much easier than 2wd gbox), just unbolt everything around and gbox split with a bit of pressure, then you need to remove two races of output shaft and diff bearings from gbox case and put them back on bearings (or if you change bearings you can throw old races to the bin), put a little bit of grease and stick around 10 mm long and 1.5 mm OD solder on top of the bearings (two/three 'sticks' of solder on each bearing) then fit back half case and bolt back up to required torque.
    Now you need to split gbox again and measure thickness of squeezed solder and chose the right thickness of the shims (about 20 sizes to chose from), and here is a little tip, the shims are available ONLY through a dealer AND is a 10-14 DAYS SPECIAL ORDER ONLY, so bare in mind that you end up without a car for a bit unless you contact with very keen guys like Nick Mann and richy rich and they help you to source shims and even supply the right ones (THANKS)

    All details you can get from manual supply in link above, here is just few main ones

    -input shaft bearing end float/play 0.05-0.17 mm
    -output shaft bearing preload 0.13-0.18 mm
    -diff bearing preload 0.05-0.11 mm

    Below is a few pictures done during the process so if any one not feel to confident have a look and see it is not that difficult as it seems.

    gbox 010 (Medium).JPGgbox 011 (Medium).JPGgbox 013 (Medium).JPGgbox 016 (Medium).JPGgbox 017 (Medium).JPGgbox 018 (Medium).JPGgbox 020 (Medium).JPGgbox 021 (Medium).JPG
    Last edited by adaxo; 22-04-2012 at 11:47 AM.

  11. #11
    Nick Mann's Avatar

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    Nice one Adam! Considering this myself too now.

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    adaxo's Avatar

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    One more thing to consider that you need something like this to remove bearing races (middle picture)

    X654822.jpg

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    adaxo's Avatar

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    Quote Originally Posted by Nick Mann View Post
    Nice one Adam! Considering this myself too now.
    Well worth doing, gears feel much firmer/easier to operate now.

  14. #14
    BraindG's Avatar

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    Looks good Adam, glad to hear you are happier with the way its driving now!

    I do have a question though, on several occasions now i have read about getting flywheel skimmed, is this just for standard flywheel? uprated? I didnt do this for the spec kit i got.

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    adaxo's Avatar

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    AFAIK skimmed flywheel makes new clutch plate wear evenly from both sides, its very common process (usually incl in every clutch job) in PL, not very common here in UK. After I remove my old clutch and inspect flywheel it seems in good state and because of lack of places who skim fly wheel around me I decide not do that and it seems fine.

  16. #16
    Nick Mann's Avatar

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    I was under the impression that the only reason to skim a flywheel is to provide a flat surface for a new clutch. If the flywheel is new, then there is no point as the surface is flat anyway.

  17. #17
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    Ok cool, thanks for clarifying.

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    just wandering, hard to find on net, but what is shimming? and whats the purpose of it?

  19. #19
    adaxo's Avatar

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    Basically is to set right amount of pre load (on diff and output shaft bearings) and end play on input shaft bearing due to slight differences between each case/shafts assembly.
    More info here http://www.evo123.net/showthread.php?t=6524
    and here http://www.lancerregister.com/showthread.php?t=17637

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    Ok looks like a doable job is there nowhere where a shim kit can be bought with a selection?

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