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Dixy

Member Since: 30 Nov 2020
Location: Somerset
Posts: 51

Replacing clutch

Clutch had a judderr from stationary so decided it was time for gearbox out and change.
The only part that showed wear was the bearing but as getting it out had been an even bigger job than I expected and as the car is a keeper decided to replace all.
Box back in and although it took a while went in fairly straight forwardly.
Before putting everything back together decided to put slave in and check it opens, it does not, with peddle down and handbrake on in difflock I cant turn the crank.
What have I done wrong

9th Dec 2020 3:23pm

Paul1275s

Member Since: 21 Apr 2019
Location: East Sussex
Posts: 80

Fitted the plate backwards? Or maybe the slave not engaging with the clutch fork. 2003 Defender 110 TD5 SW
2003 Caterham 7
2006 Mini Cooper GP

9th Dec 2020 3:28pm

htb2

Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 528

As Paul says plate in wrong way round. When plate fitted correctly it looks wrong in comparison to normal clutches, dont ask me how I know this.
I had a driven plate, that was marked this side to flywheel on both sides, which helped a lot

9th Dec 2020 4:05pm

Dixy

Member Since: 30 Nov 2020
Location: Somerset
Posts: 51

Thanks gentlemen, it is what I had feared, not that the box is heavy or tricky to slide in or out on a trolly jack.

OK so for avoidance of doubt and because Valeo could not be kind and put fly wheel side on the plate. The plate is effectively flat on one side where the spline is but the other side has a top hat. Should the top hat side go to the fly wheel.

9th Dec 2020 5:37pm

htb2

Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 528

The greater projection of the centre hub on the clutch friction disc must be towards the flywheel. Both RAVE and Haynes state this and it is generally how most clutch plates are installed. As already stated some of them have a stamp indicating the flywheel side. The old OEM disc I took out has the stamp so have a closer look. Mine is stamped FW.

9th Dec 2020 7:12pm

Dixy

Member Since: 30 Nov 2020
Location: Somerset
Posts: 51

Thank you both for your help, only wasted many hours taking the box off, removing cover, turning plate and replacing. Clutch now clears.
I wish I could say lesson learnt but like most I only read the manual when nothing else works.

10th Dec 2020 11:30am

Paul1275s

Member Since: 21 Apr 2019
Location: East Sussex
Posts: 80

Glad it's sorted, it's an easy mistake to make, thankfully the vehicle I made the error on was a little bit easier to rectify! 2003 Defender 110 TD5 SW
2003 Caterham 7
2006 Mini Cooper GP

10th Dec 2020 6:41pm

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