Club 80-90 Forums

How much endfloat is permissable on my 2.1dj?
I have a noticeable clonk clonk when I lift up the flywheel pulley while the engine is on it's back.
Is a full rebuild advisable?

end play should be new 0.07-0.13mm, wear limit 0.15mm
if out then adjust via shims if possible.

Shims behind flywheel

1.5mm is 60 thou, so quite a thunk, check if out of spec before stripping it down
Best/Main reason for having the flywheel off is normally because the oil- seal is leaking

If remove note the positions of all rings, seals and shims as they come off..

In order you will find them:
Oil seal
Retainer
Seal
Spacer Washers (shims ) 025 105 281 > 291 (various from 0.24mm to 0.4mm)
Thrust washers
etc.

Maybe read this NB. in the Wiki

http://wiki.80-90.co.uk/index.php/Gearb ... ing_clutch

Thanks for the replys.
I now realise I may have asked a slightly misleading question.

I have the flywheel off already and when I lift the crankshaft pulley I have a fair bit of movement.

Am I to assume that the shims you speak of act against the back of the flywheel so when I move it with the flywheel off I get extra movement?

Rich.

I think they do, though best check that someone else agrees (Aidan?)

End float can only be checked with the flywheel (and shims) fitted.. when in its "normal" positioj it should be felt as a nice "click", not a big clunk or nothing..

Well thats a relief I will pop the flywheel back on and try again.

Thanks for your help guys.
Rich