I've got my engine apart again after ~1500 miles of use and have the perfect opportunity to fix all the things that I didn't like the first time around.

My clutch setup:

new stock exedy pressure plate
new competition clutch street clutch disc
resurfaced flywheel (done by good machine shop)

The symptom:

The clutch always seemed to engage poorly. It had plenty of grip when the pedal was out, but the transition from pedal in to pedal out was not right. If I slipped it like I do on other cars, it felt like it lost grip and I would smell hot clutch smell.

What I found:

The pressure plate still has machining marks on it. The flywheel machine marks have been broken in towards the center, but not the outside. I measured the disc with my calipers I found that it is .25 mm thicker towards the center. So, the disc isn't making full contact because it isn't the same thickness all over.

My question:

Is this normal? Should I buy a stock disc or let this one break in?

 

Did you put it in with the correct side facing the flywheel? The splined hub sits higher on one side then the other . If put in facing the wrong way , with the longer side, of the splined hub , facing the flywheel the surface of the fiber disc will not lay on the flywheel flat .The outer od will be flexed and contact the fly wheel on the outer diameter . Buy a new one because the thin center part has now been stressed and could soon fail even if replaced correctly .

 

It's in right. I do this all the time on other cars, but have never run into a clutch that felt like this.

Besides, I don't even think it would fit on there the wrong way. The spline hub would hit the e-shaft.

Also, you've misunderstood. It's the outer part that ISN'T making contact.

 

I'd be concerned that the flywheel wasn't turned properly. Might be worth a "heck with this" and get a lightweight flywheel. Or, hell, you can get used flywheels a dime a dozen.

Dale

 

The machine shop is top notch. They do big diesels, gasoline, everything. They grind cranks, shave heads, rebuild motors. Nothing wrong with the flywheel.

Like I said, I measured the disc and it is thinner towards the outside, so it isn't making contact there. The disc is the culprit without a doubt. I just want to know if it's normal for it to have a long break-in or if it should be even to begin with.

 

Even to begin with and a short break in ,I call it cure time . About one week of normal driving .

 

That's what I thought. I'm just going to get a stock mazda clutch disc and contact Competition Clutch about this one.

Thanks for the input.

 

Well regardless of the reputaion of the shop i would check the step on the flywheel. It should be +.020" (if my memory serves me correctly). At least this way you will be able to take the flywheel out of the equation.


Re-refer to the FSM to check installation... Maybe the clutch isnt fully worn in?



Really this is all you can do short of buying a new ACT setup or something.




=Ben

 

So, I've got a bad disc, but the flywheel is bad? Then, I have to buy a new aftermarket clutch kit to fix it? Sorry to sound like an *******, but that doesn't make any sense.

I've got an uneven a/m disc, so I'm going to buy an OEM disc...