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My Clutch And Flywheel Change (Picture Heavy)


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Right ill start off by saying im no mechanic.. it took me for ever... and i dont want to do it again anytime soon hah

i done it on my larry and i really wish i has a hand as the car wasnt all that high and the gearbox was heavier than i thought.. only had it set up on wheels but i worked with what i had :)

and i might not have done things right etc or how you should do ... but hey tell me whats what and ill be happy to listen! :)

anyway on to some pictures (no fancy shots was kind of grubby and wanted to try to finish it!)

got the car up to a height i first thought was plenty high enough

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whipped what under tray i had left under there off

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then took my decat pipe off

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bit of scrapage

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split my prop

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then i slid the prop out the gearbox (woops)

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prop on the floor

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took the shifter and that off

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then hunted for the bell housing bolts (only seemed to take this picture but had three long extension bars and two small ones to get to the top ones and one for the starter motor

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bolts all out and just resting while i figured out how to get it to the floor without breaking it

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dropped it onto a wheel i had laying about

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had to slide the prop back in as gearbox oil started to come out the rear of the box where i took the prop out

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old clutch intact ready to be taken off

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old clutch plate (suprised at condition of it as the abuse its had)

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old dual mass flywheel

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flywheel off

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got hungry!

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cleaned up the jun lightened flywheel (much lighter!!)

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torqued up the flywheel with new bolts and threadlock

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flywheel fitted

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new clutch kit to go in

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clutch on and alligned to what i though was right...

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box ready to be lined up

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then realised i couldnt lift the box and hold it up long enough to allign it :( so i improvised..

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eventually got it on... what a pain!!

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then done all the bell housing bolts back up.. no photos

exhaust back on

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and it all back together!

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comments/criticism welcome!!

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Hi you have done incredibly well to carry out that job with the minimum lift and on your own!! .I have done a few clutches over the years but not on my own ,you also did well with the alignment ,this can be a struggle if you don't use a mandrel first . Well done

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@dinho

Just get on and do it... If you have the space and some tools just have a go.. All I did.. I'm no mechanic as I said.. And it drives a bit better.. Like if I'm skidding it in the dry it's much easier to keep it sideways if I pop the clutch as sliding as the revs pick up quicker and the clutch's clamping force is allot better due to the updated cover and the 4puk disc dissipates heat better therefore will be up for some more abuse.. So I'll see how it goes on my next drift day :)

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  • 1 year later...

@dinho

Just get on and do it... If you have the space and some tools just have a go.. All I did.. I'm no mechanic as I said.. And it drives a bit better.. Like if I'm skidding it in the dry it's much easier to keep it sideways if I pop the clutch as sliding as the revs pick up quicker and the clutch's clamping force is allot better due to the updated cover and the 4puk disc dissipates heat better therefore will be up for some more abuse.. So I'll see how it goes on my next drift day smile.gif

Mate, really nice job there. It looks like a lot of work. Can you please tell me if it's necessary to replace the cover as well when you replace the clutch plate?

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If you are going to all the trouble of removing the gearbox then it would be wise to replace the plate, cover and bearing... Don't spoil the ship for a ha'p'orth of tar..

I'd be tempted to replace the flywheel too but I'm not too sure how long the DMFs last on the IS.... Certainly on any modern diesel I would

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replace the clutch as a kit their really is no real saving only replacing single items...if your skint you can have the flywheel welded and lightened...

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  • 3 years later...

Can I know what was the clutch kit that you have used? Flywheel is clear, a JUN lightweight unit, but what is the clutch kit type/manufacturer?

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