Help! Stray bolt has siezed flywheel

[QBALLZ]

Once your into the motions of pulling the box it's simple. The odd hold up might be stuck dowels between box and motor and or the odd stiff bolt but in all way easier than any FWD or evo box.

[Koom]

 QBALLZ said:

Once your into the motions of pulling the box it's simple. The odd hold up might be stuck dowels between box and motor and or the odd stiff bolt but in all way easier than any FWD or evo box.

And forgetting to remove the clutch fork pivot thingy which everyone does once or twice ;D

[mr.fix.it]

Longest night of my life when i was unawer of that frikn pin hahaha

[Decimate]

Can someone please tell me about this pin lol

[Guest]

Theres a 10mm hex bolt on the passengers side of gearbox sort of under the starter. Wind that out then thread a bolt into the pin its 6 or 8mm by memory and pull the pin out. Just follow your nose she'll be right.

[funkytown]

 Decimate said:

Can someone please tell me about this pin lol

as described above, then undo one of the bolts that hold in your coil pack - if you're lucky enough to have v3/6 rex. its the right size, the pin has the same thread, so wind in the little bolt a way, and then use it pull the pin out..

[Guest]

Grease it when its out makes it easier to remove/put back in. You can lever it off the gearbox/head of the bolt if its real tight.

[Decimate]

Thanks mate and to everyone for the helpful replies I'll put pics up next weekend when I find what happened.....

[Koom]

 funkytown']

[quote name='Decimate said:

Can someone please tell me about this pin lol

/quote]

as described above, then undo one of the bolts that hold in your coil pack - if you're lucky enough to have v3/6 rex. its the right size, the pin has the same thread, so wind in the little bolt a way, and then use it pull the pin out..

The cambelt covers also use a nice long bolt with a flanged head thats the right size for this task. Universal across the EJ20 range too AFAIK.

[Decimate]

Well s***. Just s***. After finally getting the gearbox off tonight (wtf to the people that can do it in 2 hours) I finally saw what must have been stopping the flywheel from rotating (there was a piece of what looked like scrap metal jammed behind the flywheel) So I got in there with a screwdriver to see if I could pry it out and ..... it was just some plastic wrap.

Not only that, but the flywheel now turns freely (well, it\'s stiff because of compression etc but I can crank the engine over a few times if I put some weight into it).

So what\'s wrong with my car?!?! I\'ll kick myself in the face if I\'ve gone through that whole exercise and it was just the starter or something lol. Still tempted to change the clutch and go 4.44 while I\'ve got the box and diff off but I\'m mainly puzzled as to what it was that was making the horrendous noise and that stopped it from starting. I thought maybe the starter wasn\'t engaging properly but that doesn\'t really explain why the car wouldn\'t roll unless the clutch was in amd it was in neutral (clutch in and in gear = no roll...)

If I get the gearbox back in which will prob take me another 2 weeks and it does the same thing someones gonna get hurt

HELP PLEASE! ??? ??? ???

[Swindog]

If you hadnt got the clutch engaged and its running on the gears teeth itll sound like death warmed up.

Maybe the clutch is just stuffed. Have to checked the flywheel is flat?

[titian]

 Decimate said:

Well s***. Just s***. After finally getting the gearbox off tonight (wtf to the people that can do it in 2 hours) I finally saw what must have been stopping the flywheel from rotating (there was a piece of what looked like scrap metal jammed behind the flywheel) So I got in there with a screwdriver to see if I could pry it out and ..... it was just some plastic wrap.

Not only that, but the flywheel now turns freely (well, it\'s stiff because of compression etc but I can crank the engine over a few times if I put some weight into it).

So what\'s wrong with my car?!?! I\'ll kick myself in the face if I\'ve gone through that whole exercise and it was just the starter or something lol. Still tempted to change the clutch and go 4.44 while I\'ve got the box and diff off but I\'m mainly puzzled as to what it was that was making the horrendous noise and that stopped it from starting. I thought maybe the starter wasn\'t engaging properly but that doesn\'t really explain why the car wouldn\'t roll unless the clutch was in amd it was in neutral (clutch in and in gear = no roll...)

If I get the gearbox back in which will prob take me another 2 weeks and it does the same thing someones gonna get hurt

HELP PLEASE! ??? ??? ???

was not expecting to hear that...where are you? can help if its Auck...Sounds like you need guidance at a hands on level....not easy at the keyboard!

[Decimate]

Well, I did note the flywheel looks rubbish, heaps of marks/residue on it, and the clutch doesn\'t look in great nick either, so maybe that\'s a possibility. I will post solme pics tonight if I remember. So maybe it was just bad timing from lack of use (I think titian mentioned clutch had stuck to flywheel or something on page 1).

Thanks for offer titian, I\'m in Nelson though!

Stumped

[titian]

Yeah its a bit far to travel for me to assist

Advise that you remove flywheel and get the clutch done by a professional the specialises in clutches..should reface the flywheel, reset the pressure plate, supply a clutch plate and release bearing and spigotl bearing. Then its sorted!

Autoclutch up here in Auck does that....Sure that it can be sent to him via courier...Neill is the expert on clutches

Remember to refit the release bearing to the fork in the gearbox before you refit the gearbox.

Release bearing is engaged after gearbox is refitted. Good luck!

[funkytown]

you should pull off the flywheel and full clutch assembly and inspect right? i havent read anywhere thats what you\'ve done, so there imght be something still hidden and fouling?

Also check the bottom stone plate that sits between the bottom dowels, Ive seen one bent over and fouling against the flywheel making a HECK of a racket.

[Decimate]

I have got the flywheel etc off, that allowed me to check condition on both sides of flywheel and clutch which is where I identified that wear on the flywheel. The release bearing also seems to seperate into two pieces....really not sure if that\'s normal or not, and when I spin it around it\'s well off centre and spins around in a lumpy/egg motion instead of in a circle.

Will take pictures later, seems like that would be the best thing to do.

[funkytown]

eeeerr... both the spigut and release bearing should be 1 (ONE) peice each.. only...

if its separated its F&CKED... that could have jammed up. if it goes egg shaped in motion that would definately cause it all to jam up as a rotating assembly lol..

i think you\'ve just worked out what went wrong dude.

pictures would be really useful. Is the pressure plate sprung in the right way and not damage to the face or spring claws? Does the clutch disc have meat on it and not showing the rivets?

[Decimate]

Indeed, the more I think about it, the more this would explain the symptoms: i.e. would roll in neutral but in gear with the clutch in, it wouldn\'t move (i.e clutch was having no effect due to farked R.B)

Also explains the noise as part of the release bearing is locked into the pressure plate so would be spinning whenever the engine was cranking regardless of clutch being engaged or not. I hope this is what it is. I\'ll stop rambling now and post some actual pics.

Oh, and yup decent meat on clutch, it\'s a bit glazed is all.

[Decimate]

OK, here we go.....

I best make reference to what I thought was the metal jamming the flywheel last night:

Then I\'ll start with clutch, not too bad:

Flywheel, pretty grubby:

So, pressure plate + release/throw out/whatever bearing:

It seems intertwined with the pressure plate - there\'s some little fingers that wrap around the pressure plate - im guessing this is normal

But then it seperates like this:

This is what it looks like form other side

But then it warps like this when pressure is applied

Not sure what it all means, hopefullt it means I just need a new clutch, TO bearing and to skim the PP.....

[Swindog]

Toast.

[Eight_dollar]

my 5c worth ( I am sparky tho)

release brgs are self centering - they will locate to the correct position and the centre will spin (with P/plate) fine

and all have that amount of free play between the P/Plate and the brg that i have seen

clutch is toast from those pics and the flywheel needs some love too

So what was the metal object that was locking everthing thing up ? - suspect whatever it was has fallen out when flywheel removed

any signs of the flywheel rubbing/grinding against something

hopes you get it all sorted mate

[Decimate]

Well sh!t thanks swindog lol. Hmm well yes flywheel certainly needs love, and I agree. when pressure is placed on the release bearing (like full weight) it will spin on a stable axis pretty consistantly) but still, what is the deal with the two sections of the release bearing? Seems weird. Thought the clutch was OK too. looks like it might be easier to replace the whole damn lot

[Swindog]

You shuoldnt mate a worn old clutch with a new or resurfaced fly wheel. Just get the whole lot new. Autoclutch will suss it and make sure the two surfaces match exactly.

[Koom]

 Decimate said:

Well sh!t thanks swindog lol. Hmm well yes flywheel certainly needs love, and I agree. when pressure is placed on the release bearing (like full weight) it will spin on a stable axis pretty consistantly) but still, what is the deal with the two sections of the release bearing? Seems weird. Thought the clutch was OK too. looks like it might be easier to replace the whole damn lot

If you look in the gap between the release bearing and the pressure plate, there is a really thin, flat metal ring attached to it. Pry that up with a large flat bladed screwdriver and the release bearing will come free from the pressure plate. Thats how you remove them.

The pdf that is linked in this thread

http://www.clubsub.org.nz/forum/index.php/topic,13807.0.html

has the details.

[Decimate]

Thanks dude, well maybe that blows my theory that the RB was the problem, I\'ll pry it apart and see how it looks.

Next question: would it be stupid to start the engine w/ the gearbox off just to make sure it wasn\'t an engine related noise?