FullmetalFD3S

Good Day All,
Hope everyone's doing ok.
I am in need of some advice regarding the install of the clutch i have purchased. I have done a fair amount of searching on the web but im unable to find any answers to my issues.

I bought a Exedy Single sports series clutch from RHDJAPAN. According to their description its a direct replacement kit for the OEM parts.
But im having an issue with the install.
We fitted the clutch and pressure plate to the flywheel, lined up and attached the gearbox, but when trying to engage and "clip" in the release / throwout bearing into the pressure plate, it would not "click" into place.
We removed the gearbox again and upon further inspection found that it looks like the clutch plate is almost too thick , there is pretty much no space for the throwout bearing to be inserted and click into place, it hits the clutch pate?
Compared to the stock setup where there is a fair amount of space for the mechanism to move forward and engage the "ring clip".

I removed the release bearing from the gearbox and with some fiddling was able to get it to click into place by hand, but it still seemed like the front of the bearing mechanism is making contact with the clutch plate.

Does anyone know if this kit must be fitted with the exedy flywheel?or is it compatible with the stock one. Has anyone fitted this kit before?

Below are some pictures of the Kit




Below are the specifications of the kit

Part Num.: ZK02HA
SPECIFICATIONS:
Disc Type: Standard (Ultra Fiber)
Cover Type: Thick type
Clamp Load (N): 9300
Spring Damper Discs: Spring Hub
Drive: Strap
Release Bearing: Included

Any help would be greatly appreciated.
Thank you
Regards
Brendon

FullmetalFD3S

Please delete this post. I somehow duplicated it.
Aplologies.

FullmetalFD3S

DaleClark

iTrader: (55)

That looks like a correct kit and everything. If you installed the clutch disc backwards (it should have something printed showing flywheel side or something) then the pressure plate would be pushed out and could cause the problem. In the picture you posted, that is showing the transmission side of the clutch disc.

Take a picture of the throwout bearing on the transmission, I'm wondering if something is wrong with that end as well.

Dale

FullmetalFD3S

Thanks for the reply Dale,
The clutch plate is marked with "T/M side" , which i take to be Transmission side. Im fairly sure i didnt install it backwards, because the friction area wouldn't even make contact with the flywheel.

T/M side of Clutch Plate. See how thick that center spring portion is?

FullmetalFD3S

In this pic the pressure plate is fitted onto the clutch plate.The red arrows are to indicate the surface of the clutch plate. Can you see how the ring mechanism of the pressure plate makes contact with the clutch plate surface? making it not possible to insert the release bearing.
Sorry im having to post these pics seperately for some reason.

FullmetalFD3S

Only way to get the release bearing fitted is to retract the whole mechanism. This is how it fits when everything is bolted to the flywheel also. But very tricky to do when the release bearing is actually fitted to the gearbox.

Does the above look right? is this the position that the mechanism should be in when fitted? Even like this the front of the release bearing could be in contact with the clutch plate.
The OEM setup has a decent gap between the release bearing and the plate .
Unfortunately i cannot get a pic of the release bearing fitted to the clutch fork on the Gearbox, im 99% certain its been fitted corectly. Not much way to mess that up.

DaleClark

iTrader: (55)

Man, that's weird. Is your flywheel stock or aftermarket?

I see what you are saying that the clutch is butted up against the ring that the release bearing needs to clip into. Good thing is that you can troubleshoot this at this point without having to stab the transmission in every time.

It may be something with that clutch kit or something. I Googled the part number and it must be a Japan only part or something.

Also many of your pictures are not working.

Dale

FullmetalFD3S

Hi Dale,
Its a stock flywheel.
Info is very thin when searching online, definitely seems to be a japan only part. But that should be cool, as i have a RHD JDM import.
i tried contacting exedy USA directly, but no response so far. I also cant see that using an exedy flywheel will resolve this issue.

Can i ask which pics arent working for you? I can see the last three i have uploaded. the others are screwed.

Thanks again, regards Brendon

DaleClark

iTrader: (55)

I only see 2 pictures in the thread, the one of the clutch and pressure plate in the box and one showing a close up of the center of the clutch/pressure plate where the input shaft goes through.

You may want to attach the pics with the forum's picture tool.

Dale

FullmetalFD3S

Hi Dale,
I've received a response back from exedy support . They have double checked the part numbers for what i have and confirmed that they match for the FD.
Below is the response from Exedy

"Yes the parts are correct.

As you tighten the pressure plate hold down bolts the diaphragm spring will move away from the clutch disc. So if the contact is only when the parts are loose and sitting on the flywheel I would not be concerned.

The bearing will only snap into the wedge collar once the pressure plate is torque to the flywheel. The gap you have pointed out is normal, without this gap the bearing would not be able to be removed from the diaphragm spring.

The top of the clutch disc spline (highest point on the clutch disc) should be about 29mm from the friction surface of the flywheel. The diaphragm spring lever height is 39mm from the friction surface of the flywheel when installed and torqued to spec with the clutch disc or spacer to simulate the clutch disc thickness.

The flywheel should have a small step, friction surface is higher than the mounting surface for the pressure plate. This step height is 0.50mm"

I am going to try the install again, i possibly didn't torque the pressure plate far enough, in fear of breaking something when i noticed the close tolerance.

I will only try it again over the weekend and report back.

Thanks very much for the advice and willingness to spend your time reading my posts.
Its really appreciated.

Hopefully this ends well !

FullmetalFD3S

Hi Dale,
Just a quick update , in order to not leave this thread hanging.

In the end the clutch and pressure plate fits and performs perfectly.

The above instructions from the supllier was correct.

Thanks again.
Regards
Brendon