freshcut

Well, after working on the above beast for the past 12 hours I've accomplished what I can do in 2 hours on the Esprit! As productive as today was my co-worker (his car) and I have managed to spend about 6 hours taking the transmission out, 3 hours working on removing/replacing the flywheel and clutch, dual mass unit that had slipped and covered the crankshaft bolts partially, and another 2.5 hours attempting (miserably) to refit the transmission. Finally just told the guy we're going to have to pick back up in the a.m. as we're both likely to begin making mistakes and breaking stuff. I have to say after this nightmare I have come to appreciate the extreme simplicity of working on the Esprit, as well as having vowed to strongly consider saying "no" the next time I'm asked to help do a transverse clutch.

Anyone else have horror stories about projects that you agreed to help on but wished you could back out of later?

Title says it all. Have an '02 that recently (just 2 days ago) stopped locking when arming the alarm, even the touchkey doesn't give the swoosh sound of the locks when used. My first indication of a problem was driving to work and attempting to lock/arm the alarm upon arrival and not hearing the doorlocks engage and having to manually lock. I've determined that it's not a faulty fob as the hazards flash when arming and disarming accompanied by the alarm light on the dash i,e, alarm works just fine aside from losing the ability to lock/unlock. Reading through the forum, it looks like the later V8's did not have a separate PDL control module and that it's all part of the alarm module (cobra 6422). If this is correct it would seem to indicate a possible fault in the alarm module. Is there anything else I can check or look at that would avoid replacement of the alarm module, or if replacement is unavoidable, does anyone know where I can source a replacement or possibly a wiring diagram since if I do replace the alarm it likely won't have similar plugs and wiring would certainly be different.

Thanks

Blake

As mentioned from a previous "hijacked" post.

Well, I got the pump pulled on Saturday, and down to the machine shop on Monday. Talking with the tech for a bit, we determined that the impeller would certainly need heating to come out without damage, however the hub likely could be pressed "cold". Unfortunately that didn't work out too well for the hub as the shop called a said that the hub was pulling nicely but suddenly snapped during the process (dollar signs went flashing through my head at this point). I contacted the guy I got my subassembly from and have been told he does have a replacement hub as they had a few from a run they did for Lotus a few years back. So at this point I'm just going to bite the bullet, order the hub and ship the whole lot over to JAE for a rebuilt unit without attempting to do anything with the impeller. Lesson learned I suppose!

Having a look through the FSM at the flywheel material removal maximum specification I seem to have found 3 different numbers. The first two in the Clutch section indicate single plate (V8) of 1.0mm maximum which does not apply since most if not all single plate units were replaced. It shows 0.75mm for the dual plate. However in the front specification section, it lists only 0.5mm and does not specify single or dual plate. So anyone know which of the 0.5 or 0.75mm specs should be used? I'm thinking 0.5mm since in my experience you should always use the smaller of any specification unless otherwise noted.

Pages of manual with conflicting specs are TDK page 6 for 0.5mm, and pages QE 13/14 for single and twin plate with specs of 1.0 and 0.75.

Just wanted to get an opinion or two on things I might need to add to my existing shopping list for a clutch replacement. So far I've got the following;

spigot bearing
clutch plates (reasonably priced set from JAE)
flywheel resurface
new retaining pin set
new pressure plate mounting bolts
new flywheel bolts
replacement seals, o-rings and roll pins for half shafts
gearbox oil
inspection of rear main engine seal


Anything else that anyone can suggest I replace or inspect while I'm in there?
I do plan to check the condition of the throwout bearing and will replace if it appears to need it.

Planning on doing this in about a month or so. Also, anyone have any reasonable ideas as to what I can use for an alignment tool? unfortunately I don't have a spare input shaft to use, so will need something easily fabricated, commonly available, or somehow to use the input shaft on my current gearbox.

Blake