Toga

Today, my first job was to assemble the release bearing with the pressure plate. I first tried to use my bench vice to press the pressure plate…hopeless! I then went to a truck specialist not far from home to use his press. It worked perfectly, and just for info the pressure was around 250-300kg to be able to place the snap ring.
Here is the new assembly




As shown by John in it’s write up, I cleaned my speed ref sensor offset and checked its offset.
The next problem was to center the clutch plate and bolt the pressure plate to the LWF. I didn’t find a clutch alignment pin…


I did place the clutch plate as shown above, then I placed the pressure plate but didn’t bolt it too tight. Using a socket trough the release bearing, I centered the clutch the best I could. I called my son to have two more arms, and cautiously we carried the gearbox to try to introduce its shaft into the pressure plate/ clutch assembly. Moving the end of the gearbox to give the shaft a chance to move the clutch to the correct position and enter the flywheel bearing. It worked after just a couple of tries. The gearbox was place completely to its final position then through the holes of the slave cylinder and the starter, I Tightened two screws.


We removed the gearbox horizontally. I torqued the screw to their value, maintained the release fork with a sticker and replace the gearbox with the engine. Done! It’s of course much easier if you have an alignment pin like the one shown by Jason Andreas, but my system works!

The release lever shaft was placed back to its position with two new bearing and seals.


Before replacing the bearing cover and the retaining plate and screw, I introduced a piece of cloth into the hole to avoid one of those parts to fall to the bottom if I had a finger trouble when trying to place them. This would have meant remove the gearbox again to recover it!


The job is over!


…and my garage is clean! (highly appreciated by the wife!!!).

I drained the tranny oil and cleaned the magnet of the drain plug. And to refill the new oil (Mobil 1 75w90 as recommended by some of you to reduce the gearbox noise) I used my brake bleeder on which I had remove the brake fluid accu cover at the end of the plastic tube. I introduced that tube in the filling opening, and it went quite fast to refill something close to 4.5liters.
So now all the jobs planned in my project are done. I added a couple more though: the distribution covers and rotors replacement. The double distributor belt and may be the spark plugs cables.
This will probably be done end of the month or in february when I'll get all the parts available.
Now it's time for a break!!!

Any questions and suggestions are welcome.

kris

Toga,
I am in complete admiration for your project, if you allow it I will come along the day you turn on the ignition with a bottle of champaign. Good luck.
Kris
ps 1 Who do you fly for, we've probably already talked to eachother (Maastricht ATC)
ps 2 Have you seen the C4S for sale on www.kapaza.be, a stunning black beauty with only 75.000 km on it?
ps 3 Do you know the reputation of Verdoodt in Meise, the Posrche Pyramid near the A12 to Antwerp?

Fred, Long Island

Where's the ring gear?
I heard about a guy who actually threw it out with the old clutch and reinstalled the engine only to find out that you can't start it without a gear for the starter to mate with. Don't ask me who it was!!!!!

Toga

Hi Fred, Iwon't laugh on that one until I have driven my car for a few miles after this project
But about the ring gear I'm sure it's on
first pict without, 2nd with it:

Jeff96-993

I'm getting psyched to follow in Toga's footsteps... I need to sit-down for awhile and come to my senses

Great job, and thanks so much for sharing!