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clutch alignment and flywheel 

 

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 Post subject: clutch alignment and flywheel
Posted: Mon Dec 03, 2012 2:28 pm 
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Ride: 1987 telstar/2004 BA XR6 5spd

Location: Newcastle
NSW, Australia

hey guys...im throwing the 5spd conversion into the trusty coon in the next week, i just have a few little questions...how do i center the clutch plate with out a clutch alignment tool? and what is a good price to pay to get the flywheel machined around newcastle NSW? eveything that im using came out of the donor car and looks pretty good to me...
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 Post subject: Re: clutch alignment and flywheel
Posted: Mon Dec 03, 2012 2:53 pm 
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I'd buy an clutch alignment tool , or get a blown t5 for cheap and take out the input shaft .

I tried lining it up by eye but had no luck , I had a spare t5 which I took the input shaft from .
even when it was aligned the box was still hard to push in.

I can sell you the one I used , have to use for it now I'm going 6 speed

 

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 Post subject: Re: clutch alignment and flywheel
Posted: Mon Dec 03, 2012 2:58 pm 
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Ride: 1987 telstar/2004 BA XR6 5spd

Location: Newcastle
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thanks :) ill let you know...ill call up repco and super cheap and get some prices on the tool...any ideas what i will be paying to get the flywheel machined?
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 Post subject: Re: clutch alignment and flywheel
Posted: Mon Dec 03, 2012 3:00 pm 
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Location: albion park, wollongong
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Probably under $100 . Only a guess .

 

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Dark Agents,Sunroof, bilstein shocks, 6000k HIDS, 329 mm slotted rotors, twin pot calipers , Climate Control, GarrettT04 turbo,log manifold, crow turbo cam, microtech lt10c, 42lb injectors , 044, surge tank , T56 , rebuilt bottom end , alloy plenum .

Aiming for 300 rwkw

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 Post subject: Re: clutch alignment and flywheel
Posted: Mon Dec 03, 2012 4:20 pm 
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Ride: 5.0 AU's and 5.0 Maverick

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Location: Sydney West
NSW, Australia

The clutch place you get the flywheel machined at should have the plastic alignment tools available.
They are only $5 or so.

 

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 Post subject: Re: clutch alignment and flywheel
Posted: Tue Dec 04, 2012 11:07 am 
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For many years I have just used a my eye and a torch.....still works.
The only ones I can't line up are Twin Plate clutches.....definately need a tool for those.....with alignment splines.

 

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 Post subject: Re: clutch alignment and flywheel
Posted: Tue Dec 04, 2012 11:19 am 
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Ride: EL Fairmont, VFR400 racer

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VIC, Australia

Have always aligned it by eye and haven't had issues. In saying that, if the plastic tool EVL098 mentioned is only $5, I'd say use that for it will probably be much easier.

 

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 Post subject: Re: clutch alignment and flywheel
Posted: Tue Dec 04, 2012 11:57 am 
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a good quality clutch alignment tool is about $55-$60, but on Falcons, I've always just done it by eye or used my finger lol, always worked fine.

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 Post subject: Re: clutch alignment and flywheel
Posted: Tue Dec 04, 2012 6:41 pm 
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As above, used eye and even a texta with tape.

Just get it as centre as you can.

nip the retaining bolts up a touch and slot in the box without the bell housing.
remove box, tighten bolts.

or

tighten it all up, install the bell housing, try to slide in the box, if you can't get someone to lever the clutch fork or lightly press in the clutch whilst your sliding in the gearbox, it'll centre itself.

 

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 Post subject: Re: clutch alignment and flywheel
Posted: Wed Dec 05, 2012 2:32 pm 
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Ride: 1987 telstar/2004 BA XR6 5spd

Location: Newcastle
NSW, Australia

thx for your help guys, once i can get my hands on a torque wrench ill getting to work! lol any tips on doing rear main seal? motor is still out of car so access is no issue at all
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 Post subject: Re: clutch alignment and flywheel
Posted: Wed Dec 05, 2012 6:07 pm 
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Ride: Subaru Liberty RX Wagon MY03

Location: North Richmond
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Rear main seal:

Get 2 self tapping screws of an appropriate size, ie. small enough not to cause damage to the crankshaft or the block. Drive them into the old seal and use a pair of pliers to pull it out.

To install the new one, lube up the inside of the seal with CLEAN engine oil. Then find a piece of pipe or large socket the same size as the seal and use that to drive the seal home in conjunction with a hammer. Make sure that the seal is going in straight and square, otherwise you could destroy the seal.

 

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 Post subject: Re: clutch alignment and flywheel
Posted: Thu Dec 06, 2012 10:36 pm 
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Easiest way to do the box - fit the bell housing n clutch up by eye so it's close, fit the box up as far as possible, have someone slowly push the clutch in while you push the box in. Done.
No tool, no struggling.

 

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 Post subject: Re: clutch alignment and flywheel
Posted: Thu Dec 06, 2012 10:45 pm 
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krisisdog wrote:
Easiest way to do the box - fit the bell housing n clutch up by eye so it's close, fit the box up as far as possible, have someone slowly push the clutch in while you push the box in. Done.
No tool, no struggling.



beat me to it - this works every time - every clutch I've done I line it up as much as possible, start to bring it together (sliding it on a couple of long bolts or threaded rod ) then I put a little pressure bringing the two together from inside the car (big screwdriver through the shifter hole onto the back of the gearbox) - really, not much pressure at all, then just depress the clutch while you're sitting there and watch it all just slide home, easy as....

 

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 Post subject: Re: clutch alignment and flywheel
Posted: Fri Dec 07, 2012 12:25 am 
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Ride: 1987 telstar/2004 BA XR6 5spd

Location: Newcastle
NSW, Australia

i did the rear main today, was a bastard to get out but got there eventually, for the clutch i got a screw driver and just rolled duck tape onto to it till it was a tight fit into the crank..put the clutch plate on it then the pressure plate..made sure it all looked centered and even...then tightend all the bolts and put the gear box in...it slid in fairly easy...bolted it all up with no dramas :)
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 Post subject: Re: clutch alignment and flywheel
Posted: Fri Dec 07, 2012 8:04 am 
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I was going to say that if you have someone nearby you just get them to put their heavy left foot onclutch pedal and wiggle the thing in. I first used a tool (a rather largge punch) and then thought wtf am I bothering with this for? Only hard part for me and my old timers back is getting out from under the car to rig up a stick and string to hold clutch in whilst input shaft goes through. The string is to pull stick out so that the clutch doesnt release unexpectedly when my fingers are in the area.

My clutch is Exeedy HD and it is tight getting input shaft in, so a good deal of wiggling and pressure is used. But good you found a way.

Seriously easy. Push clutch in. Push t5 forwards and wiggle. Done.
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