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da houghsta Profile
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Date Registered: 05-2013
Location: Southern River, WA
TOTAL POSTS: 38
Reply | QUOTE
Single Mass Flywheel Clutch Kit issues


Hi guys,

I've had a look through here and have not found the specific issue I am having. I had a slipping clutch in my 2006 T30 X-Trail and eventually realised I would have to get it replaced. I decided to go with the Single Mass Flywheel kit as it was recommended by a lot of people on here as well as a few mechanics I talked to. I managed to find someone who advertised on a local FB X-Trail forum who was $200 cheaper than the next cheapest mechanic at $800 for the Exedy kit and $800 for labour. So booked him in to get it done. After 2 false starts (first time he pulled everything out before realising the bearing wasn't in the kit, he re-ordered the kit. Then this kit had 8 holes in the flywheel instead of 6 - or vice versa, I forget, so then he got another Exedy kit and fitted that). It didn't feel 100% right away, but he said that it would take 1000km to bed in properly - the take up point was extremely low, basically engaging the clutch as soon as I lifted the clutch pedal at all. On another note, on the way home I discovered my radiator had cracked the head, he denied breaking it (I can see what's happened, he didn't disconnect the radiator hose when he took apart the gearbox and it has shifted, cracking the head). I installed a new radiator and I babied the car around for the next 700km. He said he had adjusted the clutch pedal as much as possible and there was no more adjustment available, yet especially after having driven around about 10km or more - the clutch take up point seemed to be an inch below the firewall - it was crunching when changing gears and was even stuck at lights for a couple minutes at times as I could not force it into any gear. Feeling rather poor at this stage and knowing there was another 8 hours of labour just to look and diagnose the problem if there was one, I persisted and even did a trip to and from Karratha, but the problem persisted. Finally I contacted him again, showed him some videos of the issue happening - not being able to engage gears and asked what was wrong - it was getting worse.
His response :"Hello mate I noticed that too but I think the clutch cylinder is just not stroking enough and I can't adjust that but this was one the issues many complain about with conversions"
Now, my main question is this - is this a known complaint about this conversion? I don't recall seeing anyone have this issue before. I have since taken the car to another mechanic who replaced the hose and the Master and Slave cylinders and managed to increase the length of the pushrod. It now performs great, but this mechanic says that the wrong parts must have been used as there is no way there needs to be that much adjustment, to the very limits of what adjustment there is available. He's done the conversion himself before and had none of the issues I was having. I know this is a little bit of a rant, considering I am finally happy with the way the clutch is performing, but after paying nearly $2k and not able to fix the problem and another mechanic is able to resolve it for $350.

Is this a common problem and if so, do Exedy know they are producing a kit that is so problematic?

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2006 X-Trail Ti 5spd Manual
50mm Strut Spacers from Superior Engineering
235/70 R16 Toyo Open Country tyres x5
Hella spotlights
Alpine double DIN head unit

Ben Hough - X-3108
15/Dec/2017, 1:41 am Link to this post Send Email PM   Send Private Message Blog
 
Wiz Au Profile
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Date Registered: 06-2017
Location: Canberra, ACT
TOTAL POSTS: 170
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Re: Single Mass Flywheel Clutch Kit issues


Only thing I can suggest reading the whole story, the "bearing" that was missing, it was the THRUST bearing? (not Spigot bearing?)

If so, based on the change in travel/actuation, I'll bet they have shipped the WRONG thrust bearing.

On one particular car I own, there are two different thrust bearings. One with a FLAT face and one with a CURVED face. You get similar sort of problems if you put the curved face one in a gearbox that had a flat faced bearing, as the flat face was just a shim added onto the curved face bearing, hence changing the position of the release fork and slave cylinder rod, etc.

]Flat Face vs Curved Face Thrust Bearing

---
2004 T30 series II, Ti for now.
JRR50 Pathfinder, QD32ETi Turbo Diesel, with 'lots o fruit'.
Was looking for a white or silver 2011-2013 T31 TL (Diesel) to "pimp out".
But now moving to a 2012 Jeep Cherokee KK CRD Limited.
16/Dec/2017, 7:02 pm Link to this post Send Email PM   Send Private Message Blog
 
da houghsta Profile
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Date Registered: 05-2013
Location: Southern River, WA
TOTAL POSTS: 38
Reply | QUOTE
Re: Single Mass Flywheel Clutch Kit issues


quote:

Wiz Au wrote:

Only thing I can suggest reading the whole story, the "bearing" that was missing, it was the THRUST bearing? (not Spigot bearing?)

If so, based on the change in travel/actuation, I'll bet they have shipped the WRONG thrust bearing.

On one particular car I own, there are two different thrust bearings. One with a FLAT face and one with a CURVED face. You get similar sort of problems if you put the curved face one in a gearbox that had a flat faced bearing, as the flat face was just a shim added onto the curved face bearing, hence changing the position of the release fork and slave cylinder rod, etc.

]Flat Face vs Curved Face Thrust Bearing



Looking back at the conversation with him, it was the Spigot bearing that was missing. He ended up putting my old clutch all back in and ordered a whole new kit and was 2 weeks before he got the new kit in. This one he opened and checked all the parts were there. All good this time. So kit1 was missing the spigot bearing, kit 2 had the wrong flywheel (he called me that time so do not have any record of what exactly he said besides a couple of photos showing one with 8 studs and another with 6 studs). The 3rd attempt he managed to replace just the flywheel and used the rest of Kit 2. I think I understand about the 2 thrust bearings types, it is possible he hasn't got the correct one and is why it needs that extra pedal travel to push the clutch enough.

After he finally fitted the clutch, he then admitted he had never done a 4x4 clutch before or worked on an X-Trail before despite posting up on an X-Trail FB group advertising that he can do it. My radiator was cracked as well, if I didn't say so before, when I picked up the car and one of the engine mount bolts located under the radiator was sheered off completely as it turned out that the welded nut on the top had come loose and the bolt was just spinning, so he had to cut it off but said there is still enough support.


Last edited by da houghsta, 16/Dec/2017, 7:30 pm


---
2006 X-Trail Ti 5spd Manual
50mm Strut Spacers from Superior Engineering
235/70 R16 Toyo Open Country tyres x5
Hella spotlights
Alpine double DIN head unit

Ben Hough - X-3108
16/Dec/2017, 7:25 pm Link to this post Send Email PM   Send Private Message Blog
 


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