\(>o<)/ wo bu jiu dao - i dont know

Tuesday, August 16, 2011

Gearbox Drop Part 9 - In You GO!

Beefed up stock clutch. Uses a new chro molloy pressure plate, same diaphram and outer cover.

i am using a kevlar clutch material, more expensive than ceramic. but it came recommend for spirited track and a daily driver

below is photos of a clutch alignment tool that trys to centre it withint the clutch cover.
takes a bit of practice to get use to the config of it

i haven't driven yet but i have tested the clutch pedal. feels the same as stock.
can't check engagement though, no starter motor or exhaust yet.
clutch cover bolts i believe were 23NM, I also used high temp loctite. and do them up in an opposing pattern. slowly bringing up to torque spec

Clutch Mechanics

Additional Info:
i sent my oem to get modified.
oem was from Kenobi - around $450-500AUD
then another ~$400 or so to get it modified, this was all done via Extreme. I posted it over to SA - Gavin
all up it took a couple weeks.
I went a Kevlar disc over ceramic. I believe i am the only with this? hence it costed a bit more for RnD
Read about Kevlar here: Kevlar Disc
He was still in development of the lightened flywheel... As of mid 2012 he now has a lightweight flywheel.
Bonalume does a lightweight kit but you must use there clutch as well.

No idea what a Kevlar kit off the shelf costs. I do still have my OEM clutch disc, if anyone wants to reuse it with a rebuilt cover...
OR i can probably get my old cover rebuilt and add the new clutch disc to it...but you will have to reuse your old throw out bearing/clutch fork...mine was in pretty good nick...it did get cleaned and re-greased when i did the DiY LSD install.

Additional Weight Info:
Stock Clutch Assy = 12kg
Stock Flywheel = 6.7kg

Lightened Clutch Assy by ColtSpeed = 9kg

Lightened Flywheel by ColtSpeed = 4.6kg

By ColtSpeed Clutch

Crimping pressure -> 143%
Torque clutch design -> 150%
Corresponding torque (catalog value) 21.4Kgfm -> 32.0Kgfm -> 150%
Clutch pedal depressing force -> 123%

Some info i got from the Colt Speed Clutch

※ Notice of Work Please read the instructions that come with working before. And contains an important announcement. The excerpt shown attached below the important part is at the same time please do the following genuine replacement.

Starting from Genuine Parts required (Please do not think durability reuse) flywheel bolts ·

Genuine part Md008839 [Flywheel Bolts (M12 x 26mm)] @ ¥ 230 (tax) number five must release bearing
· ASSY (including Hawk) 2960A042 [clutch release module] Genuine Part @ ¥ 6, 850 (excluding tax) quantity 1
• Drive shaft oil seal genuine Part Number 2960A032 [oil seal diff case] @ ¥ 2,400 (tax) number 2 must
· Farukuramu (plastic pivots) 2960A031 [FULCRUM,CLUTCH RELEASE FORK] Genuine part @ ¥ 1,050 (tax) number one need

5 Part Numbers Include:
MD008839 Flywheel bolt - Five - ¥ 230
2960A042 Release bearing ASSY - One - ¥ 6,850
2960A032 Drive shaft oil seal - Two - ¥ 2,400
2960A031 Fulcrum (pivot) - One - ¥ 1,050

However i didn't replace my flywheel bolts @_@

Gearbox Drop Part 8 - Morning Shopping Run ^_^

Bought some new parts. Swaylink bushes i think they were 2 or 4 bucks each. Trying to replicate what R's Racing Garage in Japan provide. Our bushes are unique in that the ID is 8mm and the OD is ??
I can't remember. But anyways the typical universal bush of ID 8mm will have a small OD.

Had to get a new air compressor hose $55 from Enzed

And the bush with the correct OD will have a larger ID (10mm). Which is what i bought and plan to modify with a insert.
I always got the universal 12mm camber bolts. 65AUD a pair.

Had to get the flywheel machined, $45AUD
By CBA in Malaga.
CBA - Clutch & Brake Australia. Western Australia. 20 Oxleigh Dr. Malaga WA 6090

Pretty! Get the flywheel ground now lathe.
Need to use loctite on the flywheel bolts. Torque was 123NM.
I put all 5 in and then take one out at a time and add loctite.
Slowly increase torque on each bolt, do opposite bolts.

i put loctite on the last threads then use my finger to run it into the threads

Sunday, August 14, 2011

Gearbox Drop Part 7 - Broken Gear Linkage Cable Rubber @_@

Empty engine bag :)
And my broken rubber linkage. Can this be replaced?
Any one know? Rather than the entire linkage cable.

Todd, recommended some DSM shifter bearings...Trying to figure out how to attach them when the shifter link looks like a lightbulb??? Any ideas

Gearbox Drop Part 6 - Clutch Fork Install

Used a rattle gun to remove the flywheel bolts

No oil on the oil seal behind the flywheel :D

Flywheel in bad nik

New clutch fork and pivot. Used some grease on the pivot and the slide.
Requires a female torx bit to remove the fork.
I noticed the grease had a lot of dust in it. Must of picked it up from the burning clutch

Gearbox Drop Part 5 - Clutch Out!

Need a female torx pit to remove clutch/flywheel bolts

YAY its off

Seriously more slippage than i expected

Will measure clutch disc later...
I did measure it at .88mm and 1mm in some areas.
Limit is .3mm

Gearbox Drop Part 4 - Axles

Drop the GB oil before axles are removed!!!!!!!!!!!!!!
Its still purple to my surprise...I used gla4/5 75w-90 royal purple
10k km and 3 track days ago

Custom oil filler and removal of passenger axle...use some elbow grease and a crow bar. A circlip locks it in

Once axles are out...you got a few more things before your gb is out ;)
Will update more details later.

Gearbox Drop Part 3 - Demolished Brakes & Swaybar Linkage

Pretty much brand new brakes, with 10k km on it/ and 3 track days....
They are SHOT!

Removal of swaybar linkage (left) and start motor (right)

Gearbox Drop Part 2 - Tools

Spanners, geared spanners, 1/4, 3/8 and 1/2" socket sets, torx female and male pits for a 1/2" ratchet, clutch universal alignment tool, tie rod separator, hex bits, various plier and vice grips

under the car.
need to unbolt front pipe, engine damper (red thing), clutch finger thing (black thing [2 bolts])
Turbo outlet to fmic [2bolts], if you dont you cant get to the bolt for the gearbox bell housing removal