t25 1.9 dg petrol clutch out .. engine need taking out?!

[xpress]

cheers all, will get that ready. Rev, i have beer but not a bloke to do it (anyone?) unless you count the eejit man in the mirror, and mm, good idea, i will have a *very* big swear tin ready.

[Mocki]

Something to get the old starter support/pilot bush out?

Once the starter is off and the bell housing is off the engine it will just push out with one of the top bolts for the bell housing , no hassles

Forgot the 8mm Allen key cos my camper don't need one !

And we don't swear down in the flat lands !

[AdrianC]

Something to get the old starter support/pilot bush out?

Once the starter is off and the bell housing is off the engine it will just push out with one of the top bolts for the bell housing , no hassles

Ah, OK - what if the engine's still on? I've got one sat here to do at some stage, but <fingers crossed> no need to split engine and box. Just take a bolt out, use it, then put it back?

[Mocki]

Something to get the old starter support/pilot bush out?

Once the starter is off and the bell housing is off the engine it will just push out with one of the top bolts for the bell housing , no hassles

Ah, OK - what if the engine's still on? I've got one sat here to do at some stage, but <fingers crossed> no need to split engine and box. Just take a bolt out, use it, then put it back?

Unfortunately not so simples with the bell housing connected..... You will need a "Rawl bolt" of the right size, put it in and expand it enough to get hold of the bushing and pull it out. Don't be tempted to break it up with a chisel unless that is the only option left .

[AdrianC]

Unfortunately not so simples

It never is, is it? <groan>

[madjak]

i might measure the lever arm travel (how many mm should it travel for the cylinders to be ruled out as the problem with the clutch?) to make sure and rule out any problem with the master cylinder which i haven't replaced.

I asked this yesterday, I did go though the search and found "about an inch" or over 20mm was mentioned but not confirmed. I measured mine yesterday and got 14mm at the slave end of the lever. However I have gear selection/crunching issues.

kevtherev explained that if its not dragging with the clutch depressed and in gear is not likely to be causing issues.

[xpress]

i am building up to the possible inevitable, getting the box off. thank you everyone.

ps would i possibly need a helicoil for the pilot bearing, a wheel bolt and then a hub puller to get the old pilot bearing out?

to the previous poster, do you know, i have never felt the clutch slip ever, but i had gear crunching selection issues, but now, it's lurching even with the clutch pedal on the floor.. i will measure slave travel and get back to you on what i find, maybe i will find it needs a new clutch master cylinder? i replaced the slave.

[xpress]

hi there, just a quick one, is it common to have to replace the dual mass flywheel with these boxes when the clutch needs doing, and what sort of price would you work that out to be?

[AdrianC]

hi there, just a quick one, is it common to have to replace the dual mass flywheel with these boxes when the clutch needs doing, and what sort of price would you work that out to be?

I think there's some crossed wires somewhere. Does the bloke who you spoke to think it's a T5, by any chance?

[xpress]

i hope not!

would there be a chance of a flywheel need replacing in the equation? i am trying to ascertain the worst case scenario compared to the best case scenario. ie bearing breaking up/needing replacing/clutch disc/fork/....

...flywheel? (go on, how much...)

[AdrianC]

would there be a chance of a flywheel need replacing in the equation?

No.*

I've never heard of a DMF on any petrol engine, and they aren't on diesel T25s, either. They're a recent thing.

* - well, there _might_ be. If the old clutch has worn so badly that it's chewed the friction face up that it can't be machined and stay within the minimum thickness. In which case, a good used flywheel shouldn't be expensive.

[xpress]

thanks for the replies. these quick fit clutch places, i wonder if they bother refacing a flywheel or would they send out for a new one? seems that some clutch places want to replace a flywheel with the clutch plate.

[AdrianC]

I don't know quite how best to put this...

IGNORE THE FLYWHEEL. IT'S FINE.

And - please - don't go near a "fast-fit" place of ANY flavour. Find a real garage.

[xpress]

CHIP BUTTY AND A 10 CAN OF STELLA AR TWAR FOR THE BRAVE MAN WHO MAKES THESE FOUR WHEELS WALK AGIN!!!!!!!!!!!!!!!!!!!!!!!

[California Dreamin]

Dual mass flywheels are a relatively new invention, the first appeared many years after the 'Wedge'. However, flywheels should be checked during a clutch replacement...the clutch surface should be inspected for surface cracking, blue 'high spotting', grooving (usually caused by allowing the centre plate to wear to the rivets) and ring gear teeth for damage.
Chances are the flywheel will be serviceable but checking should be all part of the process.
And yes...if the flywheel is worn badly in some way it might need re-facing.

Martin