Clutch Alignment

[brainbug007]

I'm trying to re-connect my gearbox to engine and I'm struggling to get the clutch plate aligned correctly so that the gearbox slots in nicely (currently seem to end up with a cm gap between the engine and bell). Is it worth buying one of these tools or is there a more locost way to do it?

[davedew]

Have you take the clutch assembly apart? If not you should not need an alignment tool. It sounds like the bell housing may just be caught up on the dowels. Try putting the bolts through the two dowel positions and do them up to pull the engine and box together.

I had to do this on mine the first time. After that when it came to the final engine fit it went together easy.

[brainbug007]

Yes I took the pressure plate and friction disc off the flywheel to mount my engine on a stand so I could strip it down and clean it up. Just thought maybe I've not got the friction disc lined up correctly which is causing the gap?

[Luke2842]

I had the same problem trying to line my new clutch up by eye, after many attempts I gave up and brought a cheap laser one from halfords was only £13 something with a trade card and well worth the money!

[brainbug007]

Well some articles I've been reading where suggesting using a 1/2" socket wrench and then wrapping a load of tape around it, wondering how well this will work.. Also does anyone have a good picture of which way round the friction plate should go? the picture I took hasn't come out that well so its hard to tell now if I've got it on the right way round :S

[ozzy1]

Is the friction plate not marked for which way round it goes? Im sure the one ive got is.

[brainbug007]

Not sure what you mean by marked?

[ozzy1]

I think mine has which way round it goes stamped into it.

[Luke2842]

I'm using the dohc and my clutch had the projecting torsion spring hub on the opposite side of the flywheel, hope that makes sense.

[davedew]

If you can get them with a gap of 1cm to each other I would say that the gearbox input shaft has already gone into the friction plate.

I'd give the bolts a go at pulling them together. Nothing to loose.

[baz-r]

i did mine by eye as i must have lost my alignment tool
a easy way to eye it up is to look not at the center but around the edge of the friction plate in the gaps and check the lip distence of the pressure plate to friction plate my one was edge to edge.
also put the box in gear and turn the output to get the splines lined up

[brainbug007]

Well I checked when I got home last night and I'd made a few mistakes... It wasn't aligned properly and I had the friction disc the wrong way round... I then tried to take the pressure plate back off to fix it only to discover I must've put the bolts on way to tight as they wouldn't budge. I then proceeded to split every 10mm socket I had (about 6) trying to loosen them and managed to round off the heads on most of the bolts in the process. In the end I got the chisel out and had to practically dig away under the bolts to release enough pressure to get them out by hammering a 5/8 socket on as it was the closest I had left at this point. So my pressure plate is pretty much ruined I guess but my flywheel is ok. I'm guessing now I need to buy a new clutch kit as it's pointless to only replace the pressure plate :( Anyone know if the clutch kits on ebay are any good or a waste of money?

[baz-r]

i have a almost new sierra 1.8 cvh clutch complete
the guy who had my sierra must have spent loads as there was all sorts of almost new stuff on the old girl
as it was cheaper to buy a new clutch than to get my zetec flywheel re drilled and ballanced i did that :)

[K4KEV]

Might be worth factoring in a torque wrench as well:p :p...as for alignment I use a straight wooden dowel or 1/2" long extension with leccy or gaffer tape to make up the two diameters needed

[Bonzo]

As for alignment I use a straight wooden dowel or 1/2" long extension with leccy or gaffer tape to make up the two diameters needed

Snap :)

I have changed dozens of clutches over the years & never use anything other than a dowel n insulation tape as an alignment tool.

Looked at proper tools loads of times but being a tight ass dickwad couldn't bring myself to splash the cash :rolleyes: :D :D

[brainbug007]

Well my local autofactors will do me a new clutch kit for 65 quid which didn't seem too bad compared to 70-90 quid from ebay. Only part I'm struggling to find is the pressure plate bolts. The autofactor doesn't stock them and suggested contacting a local ford dealer. The ford dealer didn't know what I was talking about :(

[robo]

If the clutch is not a brand name its probably made by cadburys in some far off land. Worth thinking about when you look at the grief it is to change at a later date. As for the bolts they are nothing special so get them from a bolt supplier, The tensile rating is normally on the head of the bolt eg. 8.8 .

Bob

[tkpm]

My next door neighbour went to the local scrappy, found a buggered gear box.
He then cut the input shaft off, hey presto clutch alignment tool.

Terry

[Bonzo]

Only part I'm struggling to find is the pressure plate bolts. The autofactor doesn't stock them and suggested contacting a local ford dealer. The ford dealer didn't know what I was talking about :(


The bolts are available here

Burton Power (http://www.burtonpower.com/ft594.html)

If you should go back to the Ford dealer tell them that you need the Clutch Cover Bolts ;)

I don't know what grade of bolt they are but I have a stack of M8 X 15mm set bolts here ( 8.8 Grade )
Wouldnt be any problem to stick 6 of those in the post for you :)

[brainbug007]

Thanks for all the help with this one guys. I got the new clutch kit home today and fitted it properly this time by making sure things like the friction disk was the right way round! I managed to salvage 4 out of the 6 bolts then took some other bolts I had from the donor and just shortened them a bit with the grinder which seems to have worked fine.