1.6TD JX Bell/Clutch Housing

[torchy]

The bell/clutch housing on my JX has totaly corroded holes to the point it actually split the sump when tighnening up last time. Clearly it needed replacing. After the Salsibury green lane day I was convinced I had a slipping clutch, now the gearbox is on the deck it can be seen it was slipping because it was full of mud!!!!. The bell housing has a hole in the side at 3 oclock and a pipe at about 2 oclock position looking forward.

What are these holes for???????????? Aparantly they are for wading?? But then why did it fill up with mud?

The garage has a 2WD bell housing ready to fit and the truck is up on the ramp as I type.

Please can anyone tell me...can I fit a 2WD bell housing and if I do can I still wade with it.

I replaced the 4WD turbo with a 2WD turbo from Baxter who said that was all that was avaialble? is it the same for the Bell housing?.

............and if it is how do you wash out the clutch housing.

Look forward to comments ASAP as the garage wants it's ramp back.


Many Thanks

[Aidan]

the late syncro diesel bellhousing has those holes so that some big chunky rubber breather pipes can be attached and thus allow the clutch to breathe, in extremis the 215mm diesel clutch is on it's limit, esp in hot climes.
Yours has lost the pipes in the past obviously.
Not easy to come by and not cheap.
Yes you can fit the 2wd diesel bellhousing that's what the syncros had till 1990 (by which time the clutch wear issue must have been acknowledged) but you'll have to change the "pooh" plate behind the flywheel to match the bellhousing

[torchy]

the late syncro diesel bellhousing has those holes so that some big chunky rubber breather pipes can be attached and thus allow the clutch to breathe, in extremis the 215mm diesel clutch is on it's limit, esp in hot climes.
Yours has lost the pipes in the past obviously.
Not easy to come by and not cheap.
Yes you can fit the 2wd diesel bellhousing that's what the syncros had till 1990 (by which time the clutch wear issue must have been acknowledged) but you'll have to change the "pooh" plate behind the flywheel to match the bellhousing

Brilliant many thanks Aiden. So what you say most Syncros going around just have a normal 2WD bell housing.

But what's a pooh plate???

Does any one else have problems with the clutch filling up with mud?

[Aidan]

the s h 1 t plate (who changed the swear filter to include that loophole ) as it is commonly known is that thin metal plate that fits to the flywheel seal housing behind the flywheel and makes the effective seal with the cut out in the bellhousing that allows you to get at the sump bolts also behind the flywheel, the cut outs are different between the 2wd and late syncro bellhousings as you will see when comparing side by side, the late syncro one makes a much more effective seal and has two extra m6 bolts to clamp it tightly to the bellhousing though these are usually missing by now as most mechanics can't be arsed putting them back

so it's ok to say arsed but not s h 1 t

[torchy]

Many Thanks for the invaluable help Aidan. The 2wd had a boss in the cut out and the plan was to grind that out drill and tap a hole in the casing to secure the "pooh" plate so get up and running again.
I say "was" because I guess it has been one by now but I've had no time to pick it up so I'm assuming all OK.

But.......Now I have a 2wd clutch housing with no holes for ventilation, do I need to worry?.......baring in mind it should not be subject to "extreme" conditions, although granted some would say any off roading could be classed as extreme....slipping the clutch etc.

Longer term plan is to find a replacement 4wd bell housing or get mine fixed (anyone know any good alluminium fabricators/welders?). I'm not a purist but just feel with the bigger clutch a bit of ventilation is not a bad thing.

Thanks once again.

[alewing]

Hi Torchy,
How did you progress with your clutch housing 'issue'?
Ashley

[syncroandy]

Just seen this 'cos of the bump.

I would add that if replacing a late Syncro vented BH with a non-vented one, then it would be worth adding in a breather hose at the top. Otherwise if well-sealed, immersing the whole thing in cold water could result in oil being sucked past the seals. Another thing to consider would be to add a small drain plug at the bottom which is a Syncro-specific BH feature. Then if it does get flooded for whatever reason the water can be drained out.

[alewing]

Just seen this 'cos of the bump.

I would add that if replacing a late Syncro vented BH with a non-vented one, then it would be worth adding in a breather hose at the top. Otherwise if well-sealed, immersing the whole thing in cold water could result in oil being sucked past the seals. Another thing to consider would be to add a small drain plug at the bottom which is a Syncro-specific BH feature. Then if it does get flooded for whatever reason the water can be drained out.

Thank you syncroandy,
That was just the information i was looking for! I now understand the need for these breathers when there is the possiblity of 'quenching' a hot clutch/bell housing.

I was curious because the clutch/bell housing (091 301 107A) fitted to my 1988 JX SIKA does not have these breather ports and is also not a recognised part number in EKTA?!!?...........so i thought someone must have changed the clutch/bell housing in the past, maybe. Therefore my next questions are:-

Should this vehicle have been fitted with a breathable clutch/bell housing from new?
Is the current clutch/bell housing the correct one?
Considering i am upgrading the engine to an AAZ; do i need a clutch/bell housing with breathers?
Does anyone have or know of a spare clutch/bell housing with the breather ports that i could purchase OR is it ok to modify the existing clutch/bell housing with breather ports and drain etc?

Many thanks in advance,
Ashley

[syncropaddy]

Diesel bellhousings are getting hard to find these days so I'd modify your existing one like Andy has suggested. There are none for sale in all the usual places at the moment

[syncroandy]

Hi Ashley, I'm only familiar with the two Syncro's I've owned, both late, one petrol one TD. Both were stock with original engine/gearboxes.

The petrol has a narrow plastic breather line which attached to the bellhousing cavity via a small rubber grommet at the top (actually on the engine casing). The purpose of this appears to be to permit pressure equalisation in the event of immersion in cold water. The TD has much larger 'vents' or breathers, which appear to allow not only pressure equalisation, but cooling via air circulation. Both have small plastic bungs at the bottom of the BH.

I've not seen the 'early' TD Syncro arrangement (without the vents) described by Aidan. It would be interesting if someone could have a close look and see of there's a narrow plastic breather line fitted as on the petrol. Of course there is the ever present possibility of vehicles being non-standard as many owners will have swapped parts around..

HTH

PS. If going JX -> AAZ, you could consider upgrading the flywheel/clutch 215mm -> 228mm, which may reduce the risk of excess heat, and eliminate any need for additional cooling vents.

[torchy]

Just seen this 'cos of the bump.

I would add that if replacing a late Syncro vented BH with a non-vented one, then it would be worth adding in a breather hose at the top. Otherwise if well-sealed, immersing the whole thing in cold water could result in oil being sucked past the seals. Another thing to consider would be to add a small drain plug at the bottom which is a Syncro-specific BH feature. Then if it does get flooded for whatever reason the water can be drained out.

Thank you syncroandy,
That was just the information i was looking for! I now understand the need for these breathers when there is the possiblity of 'quenching' a hot clutch/bell housing.

I was curious because the clutch/bell housing (091 301 107A) fitted to my 1988 JX SIKA does not have these breather ports and is also not a recognised part number in EKTA?!!?...........so i thought someone must have changed the clutch/bell housing in the past, maybe. Therefore my next questions are:-

Should this vehicle have been fitted with a breathable clutch/bell housing from new?
Is the current clutch/bell housing the correct one?
Considering i am upgrading the engine to an AAZ; do i need a clutch/bell housing with breathers?
Does anyone have or know of a spare clutch/bell housing with the breather ports that i could purchase OR is it ok to modify the existing clutch/bell housing with breather ports and drain etc?

Many thanks in advance,
Ashley

Hi Ashley, I still have the 2wd BH fitted which was modified to take the "pooh" plate ref Aidens comment also a small hole drilled to drain, but hav'nt done anything extreme to test it yet. I was told the two breather pipes are required for the bigger 16" to act as cooling to the clutch. I will also upgrade to an AAZ at some point and like you would prefer to have the original BH fitted, I keep looking on E bay (plus German ebay) and elsewhere but as has been said, they are like hens teeth. However since other bits are breaking and falling off they are taking the funds at the moment so I'm rather inclined to leave it and cross fingers.

Good Luck

[alewing]

Cheers guys for all your help and suggestions. Bigger clutch and Mod to the 2wd BH it is and i'll update the thread once done