Clutch Problem...*Sorted*
Turbo Mini Forums

Will you please have a look at these pictures and someone tell me whats wrong, The diaphragm looks real close to the centre nut on the flywheel, and why is there that little bit sticking out on the plunger arm, i think its bearing on the nut when i press the clutch. spec is, new ultralite fly, grey cover, racing plate,new nut and keywasher, new slave and bearing, i hasten to add i have converted to preverto from verto. engine runs fine but cant get a gear at all.

Edited by chinlesswonder on 17th May, 2009.

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

That nipple on the bolt is a mystery... I grind it off out of principle. It does look like you could be hitting this as your plunger sticks out a long way from the bearing.

thats what i thought, what about the diaphragm, in anyones opinion is it too close to the centre bolt, how much does it move when the clutch is pressed down, i'm thinking of packing the plunger out a tad with a thick washer

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

the diaghram moves around 180 thou according to fastcarl.

whats with the spring washer on the plunger? is that a verto plunger with the bearing?

no, apparantly it is a pre verto 'wok' had the long arm on it, ill double check though. Seems odd though as the bearing is a loose fit on the shaft and only held on with that crappy retaining washer

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

Any thoughts on the diaphragm and how close it is to the centre flywheel nut?.

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

that plunger looks wrong! the bearing should be a push fit, the bearing should be about flush with the end of the plunger, and i've never seen one with the washer thing.

can we have a picture of the whole plunger?

that plunger is the same as the preverto one i'm using (with a verto flywheel lol) I think they ARE LOOSE TO MAKE THEM SELF CENTRALISING oops.

keith, its a vertro plunger you need a pre vertro one and make SURE you have the right bearing to suite!

press the bearing on the new plunger
its an interference fit and the bearing needs to go right up to the sholder on the plunger
ditch the spring clip not needed on the correct pre vertro plunger and bearing
hope this helps

what about the diaphragm cover plate, does it look like its fitted right, it looks awful close to the centre flywheel bolt

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

getting a bit confused now, i have this plunger which says its pre verto
http://www.minispares.com/Product.aspx?ty=...20PLUNGER%20L...

should i have this plunger which is also preverto
http://www.minispares.com/Product.aspx?ty=...R%20PRE%20VERTO

this one is looking favorite.

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

right kieth, the top one is the wrong one, which i guess is the one you have.
you need this one ....... http://www.minispares.com/Product.aspx?ty=...R%20PRE%20VERTO

and the correct release bearing for it, minispares north ask for richard for that plunger and the bearing to go with it.

it looks like you have a vertro relaeas bearing and the wrong plunger

Right, cheers Steve, it is ordered

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

Got the new plunger and bearing, pressed it on in the vice, nice and tight, fitted it to the car again and bolted everything up, gave it a try and its still the same, can't get a gear, arm is moving fine, running out of ideas now. Any one got any suggestions?.

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

is the bearing making contact with the pressure plate ? and the pressure plate is disengaging ?

is the slave cylinder going to its full travel ?

bearing is definately making contact with the plate, not too sure if its disengaging when i push the pedal down, it looks from my previous picture that the pressure plate is hitting the nut holding the flywheel on, theres only about 5mm between them. Is it possible the primary gear in some way is jammed into the flywheel?. As i recall, when i first ran it, the clutch worked ok for about 6 or 7 presses, got gears no prob lem when i tried it in the street, then i felt something 'give' when holding the pedal down, like the thrust bearing had moved back on its shaft, that was the last time it worked.

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

how many drive straps do you have on ?
also kieth how old is the pressure plate
this could be very weak!

brand new orange diaphragm, new lightened backplate and ultrlight flywheel, all from minisport, all balanced by them, its got 2 drive straps on each lug

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

Just had another thought, could it be the goodridge flexi pipe i'm using, it is the verto one from the previous slave cylinder, i got the pre verto slave but didn't replace the pipe.

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

What condition is the clutch arm in ? And have you correctly adjusted the throw out stop bolt ?

I had major issues with my clutch and it was the clutch arm bending due to a worn out plunger.

"So wat we gonna do tonight Brain?"
"Same thing we do evernight Pinky!"
"Try to take over the world!"

clutch arm looks ok, bit old but no cracks or serious worn bits, i got a new clevis pin just to be safe. I have wound the throw out stop nut right back just to try and eliminate that,still no joy.

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

first thing kieth, the orange wont do the duty, get a double grey buddy and make sure!

3 drive straps are better 2 will suffice.
anyway back to you problem,as long as the clutch arm is on full travel and the slave cylinder is at full out position, its not your pipe.

things to check out, you need to strip down the clutch and investigate, could be you have fitted the clutch plate wrong way around ?

or the clutch plate is jamming on dirty or bured splines on the primary gear.
keep us posted

Edited by BENROSS on 16th May, 2009.

Stripped the whole clutch apart at the weekend, soon as i released the backplate i found the problem, couldn't turn the clutch plate by hand, took flywheel off and the primary gear was stuck solid, couldn't turn it at all. Pulled it off the taper and retrieved the spacer at the back, then realized, it was on the wrong way, it has an ever so slight chamfer on one side that goes to the crank, so assembled it correctly and its fine now. can't for the life of me see how i missed this when i built it.

133.5 bhp 123 lb torque 116mph @6640rpm 9.5psi
Shakespear RWYB 14.995 91.83mph

there you go kieth, the clutch would not idle at all