Join Date: Dec 2012
Location: Lake Helen, Florida, USA
Re: Preemptive clutch repair?
After a good night sleep, I woke up reflecting on the weep hole drilling and shaft seal replacement that I did yesterday. I have a couple of suggestions that might make it easier for the next guy.
First, the jig that John Z fabricated to secure the FD for removal and install is invaluable. Reassembly would have been near impossible without it. I suggest that everyone who is going to remove the FD for any reason, study the video and make one.
Disassembly was straight forward. Fast forward to reassembly
After getting the drive shaft clicked onto the transmission output shaft... I aligned the driveshaft u-joint bearing cups horizontal to the ground... I then went to the back of the drive shaft / swingarm and scribed a mark, bottom dead center inside the swing arm housing with a felt marker and then lightly struck a corresponding mark on the end of the driveshaft with a center punch. If the driveshaft gets rotated in the process of struggling with the FD install, it is a simple matter to realign the shaft using the two marks.
Sliding the FD into the driveshaft wasn't as smooth as I hoped it would be. It did slide on twice but, it slid onto the wrong spline. I made a change in procedure by shifting the transmission into neutral. I was able to start the FD into the driveshaft to the point that the splines were engaged. If I turned the the rotor on the FD, the FD spline and driveshaft turned together, maintaining timing of the u-joints. As the components were turning, with pressure from me pushing the FD forward, the shaft and FD spline were aligning themselves with every rotation until they simply slid together.
I don't know if any of this is accepted procedure...but it worked for me. If you're struggling with reassembly in this area... give it a try. I strongly suggest indexing the rear of the driveshaft to a mark inside the swing arm to ensure maintaining proper alignment of the driveshaft u-joints.
Friends know the song in your heart, and can sing it to you when you have forgotten the words.
Last edited by FatStrat; Sep 18th, 2013 at 7:20 am.