Yesterday I swapped in a new flywheel, clutch, pressure plate, and throw-out/pilot bearings. Normally I'd yank the motor and trans as one and break them apart outside of the car, and that's how I'm doing it from now on!
I dropped the trans out the bottom just to avoid disconnecting any coolant lines... what a nightmare. At least on a rusty old Suub like mine. Anyway, on to the fun.
Started by removing the intercooler/BOV/wiring/vacuum lines and anything else that would stop me from reaching down in and plucking the old clutch out. Then crawled under to drop the exhaust, and see such lovely sights as;
Well I guess that rear differential is staying. I had also wanted to swap in a 4.11 trans I have, but maybe another time. I knew I didn't have all weekend and it was about all I could do just to get the driveshaft cover off.
Wouldn't have happened without THIS beauty, five feet of 'motivation'
Now I can slide the trans back... I think! She was stuck good, but enough yanking and swearing plus a couple thin blade screwdrivers prevailed.
Ugh, looks kinda juicy in there... Pressure plate, clutch, and flywheel next. I've definitely pulled worse looking clutches out, but if it slips, it's gotta go.
Even the throw-out bearing spun and sounded fine, maybe I'll just keep it, just in case...don't judge me!
Ok, now that the flywheel is outta the way, let's take a look:
Yup, definitely a leaking oil separator plate. Good thing I planned ahead ...not. I cleaned up the plate and the mating surfaces then liberally applied Ultra Black. That stuff is awesome.
Welp, now I can start putting it all back together. Ain't it a shame that they paint the pressure plates all these vibrant colors, and no one gets to see it?
Reassembly was MOSTLY a cakewalk, with the exception of landing the trans back on the two lower alignment dowels AND sliding the bellhousing past the turbine housing. That took everything I had and almost bested me. Finally after about two hours of raising, lowering, pushing, pulling, pounding, and praying:
Got it! After that, all I did was pump the jack under the transmission twice, and everything LITERALLY slid right together. Never seen anything like it. I was actually cheering.
So I reinstalled everything, super excited to be on the home stretch, went to start it up, and it sounds like the timing belt has suddenly skipped a tooth. Impossible. Didn't touch it. In fact, everything is EXACTLY the same except the clutch. Which I do need to adjust a little. ****** is heavy and grabs RIGHT off the floor.
First on the list is clean my throttle body. I did take a quick rag to it mid swap, and I'm thinking I spread some gunk around and messed up the idle position, or dirtied up the TPS... idk. If that doesn't do it, I'll pop off the timing cover and see what's what. Then I'll reinstall the stock injectors and see if it just has to 're-learn' it's idle. Honestly it seems like a vacuum leak, except I'm pretty sure everything is connected tightly, and the AFR's are too rich. Maybe an injector is stuck open?
Anybody know if that transmission-to-chassis ground could throw my idle? That got snapped in the process, as usual.