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Gearbox and clutch removal

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mike_sekinger

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Hi Folks,

After last weeks dyno session I needed to remove the gearbox and inspect the clutch.

All of the chargecoolers stuff removed
[img]http://img37.imagefra.me/i5cb/sekinger/grq4_662_u6qlh.jpg[/img]

Driveshafts out of the way and the gearbox slide back free of the clutch pack
[img]http://img37.imagefra.me/i5cb/sekinger/grq4_2c9_u6qlh.jpg[/img]

Gearbox lifted clear and clutch exposed for removal
[img]http://img37.imagefra.me/i5cb/sekinger/grq4_728_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i5cb/sekinger/grq4_423_u6qlh.jpg[/img]

Flywheel removed, re-faced and replaced
[img]http://img40.imagefra.me/i5cb/sekinger/grq4_4e2_u6qlh.jpg[/img]
[img]http://img40.imagefra.me/i5cb/sekinger/grq4_529_u6qlh.jpg[/img]

The clutch will now be sent off to AP to see if they can install a stonger diaphragm with a target to get somewhere close to 550Nm of clamping force.

Here are the Final Edition springs and dampers installed last week. The ride was hugely superior to what was installed before.
[img]http://img40.imagefra.me/i5cb/sekinger/grq4_258_u6qlh.jpg[/img]

Cheers,
Mike S
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Oh dear, lots of messing about.

Are there any particular reasons why the clamping pressure should be inadequate? I am intrigued - but I can't remember precisely how the clutch bolted onto the flywheel and hence, the criticality of the dimensions.

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Hi Edward,

The clamping load is fine for an engine producing standard power outputs. Even during the last dyno session with reduced boost, we are producing significantly more power than standard. With the target to be able to use greater boost, the unit is back with AP to increase the clamping load further. Depending on which technique they suggest, the release load (pedal effort) may be unchanged.

More info as I get the feedback and recommendation from AP.

Cheers,
Mike S

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Hi Dave,

Still awaiting a full set of options, but I know that my contact was at Autosport last week.

I will keep you posted !

Oh - and well done for getting your motor running :thumbsup:

Cheers,
Mike S

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Got feedback from AP.

Problem was caused by the use of Helix friction plates which are thicker and as a result, reduced the clamp load.

They are now preparing a revised spring, which when used with the correct thickness friction discs will increase the clutch capacity to over 470lb/ft. Should be enough for my power target without having to move to a bespoke push-type clutch set-up.

A result ! :thumbsup:

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Great news Mike! Will we still have the Ford 1" spline as an option with this upgrade? Got an email from the guys over at GTO, seems they will be a distributor for this clutch?

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Hi Dave,

They have ordered a number (10-off I think) of the chrome vanadium cover springs from AP and can supply them. You can also get them directly from AP.

AP can also supply the correct thickness driven plates in the Ford 1" spline.

One thing to note (which is of some concern right now), is that the release load increases from 1400N to 2000N with the CRV spring. The slave cylinder actuator rod is actually made of plastic and I´m not sure if the additional stress will lead to fatigue of this part.

Will keep you posted on findings !

Cheers,
Mike S

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My revised AP clutch is finally on it´s way back from AP.

They were not happy with he resultant clamp load from the CRV spring alone, so have moved to a different pressure plate as well.

Still yet to realise what real-world different in the release load, but after plotting the clutch looks capable of coping with 500+ lb/ft or torque.

If it arrives by Monday, then I´ll have the V8 up and running again for the first time since late December :thumbsup:

Cheers,
Mike S

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The clutch didn´t arrive yet, but everything else is ready for when it does.
[img]http://img37.imagefra.me/i536/sekinger/grq4_e4c_u6qlh.jpg[/img]

I can´t believe that I´ve got 3 of the most desireable Esprits in the garage and not one of them is actually running :construction:
[img]http://img40.imagefra.me/i536/sekinger/grq4_fed_u6qlh.jpg[/img]

Cheers,
Mike S

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The modified AP clutch arrived this morning :animier:
[img]http://img40.imagefra.me/i538/sekinger/grq4_5d1_u6qlh.jpg[/img]

Fresh flywheel degreased and ready for install
[img]http://img37.imagefra.me/i538/sekinger/grq4_1a3_u6qlh.jpg[/img]

Clutch pack installed
[img]http://img40.imagefra.me/i538/sekinger/grq4_49f_u6qlh.jpg[/img]
If you compare the position of the spring to the earlier installation, you can see how the Helix friction discs had taken the spring out to practically flat. :thumbdown:
will report back on the release load/feel next week.

Gearbox installed
[img]http://img40.imagefra.me/i538/sekinger/grq4_b87_u6qlh.jpg[/img]

I did manage to get the driveshafts installed and secured, but ran out of time for gear linkage etc.

This coming weekend should see the re-animation of both the V8 and the S4s :thumbup:

Cheers,
Mike S

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Great stuff - the V8 is back up and running.

Excellent to hear it running again for the first time since December.
Exhaust installed
[img]http://img40.imagefra.me/i53d/sekinger/grq4_6b5_u6qlh.jpg[/img]

Boot floor and chargecooler gear
[img]http://img37.imagefra.me/i53d/sekinger/grq4_20d_u6qlh.jpg[/img]

Start-up !
[img]http://img37.imagefra.me/i53d/sekinger/grq4_5f6_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i53d/sekinger/grq4_126_u6qlh.jpg[/img]

In some ways the very best news is that the clutch release load is not too bad on the revised clutch. It is certainly still feeling lighter than the S4s - so that really is a result. Hats off to the folks at AP ! :sorcerer:

Cheers,
Mike S

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Hi Mike

Sounds like excellent progress.

I continue to be particularly impressed by the seemingly single-handed approach. I regret that age and its attendant failings mean that my previous jobs-done-on-my-own ways of working are long gone. I was chatting to a colleague this morning and he is going through the same transition.

It's increasingly hard to crawl/wriggle/squirm under cars and once under, incidents where the wrong-size spanner is to hand or another tool is actually required increase. Then there is the Captain Mainwaring skewed-spectacles comedy. Not only do they get dislodged, re-positioning results in greasy finger marks that make vision even harder and to cap it all, focussing is challenged such that you can't see with them on and you can't see with them off.

However, have you managed to get out for a road test?

Also, did you get the lengthy e-mail I sent last week? I am having problems tracking things via blog-related links and attempts to verifiy that transmission occurred have been unsuccessful.

Best wishes.

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Hi Edward,

I´m not sure how the blog notification stuff works, but if you subscribe to the blog then you should receive an email when it is updates.

There are still times when my wife is needed to help me - things like removing/attaching the rear decks definitely require additional hands.

Hoping to get both cars out for a road test today.

Cheers,
Mike S

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Hey Mike,
I'm getting ready to order my transmission upgrade...

How is the new AP clutch working? Were there any adverse affects on the slave cylinder rod?

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