So last night I broke the third freakin' clutch in 6 months...

[shelldrake]

So, what is causing this to occur when I miss a gear. I had this exact scenario happen a while ago with a second hand exedy, then with a new hd exedy, then again (most recently with another second hand hd exedy) I have discussed this with a mate , and we think perhaps the gearbox spline could be a bit bent - This could explain a - the breaking of clutches and b - the unbalanced feel above 5500rpm... Any thoughts would be appreciated. At this stage I'm sourcing out a new box and a custom clutch...

[Ben Wilson]

How do they fail?

[shelldrake]

one of the 3 straps break. then the other two crinkle up...

[oldcorollas]

so the bits holding the pressure plates friction surface break off?

perhaps you are over-revving when you miss a gear, combined with wonky box or whatever...

didn7t someone else have simialr issues with the straps breaking on exedy? have a search

[shelldrake]

http://toymods.net/forums/showthread.php?t=11913

It was me mate. You replied first in the thread.

[merc-blue]

hows the spigot? nice and tight, if the spigot is sloopy that wont help

how much play do you have in the input shaft?

[shelldrake]

Was a new item 12 months ago...Might be time for another, but it has been good on inspection in the past. It was an overrev, no doubt - But why can turdinator's motor producing about the same power take so much more abuse? Also, I should add that I havent pulled the box off the most recent little spill to inspect the damage, but I can anticipate how it will look after feeling the same after the last 2 experiences...

[emp?]

i also snapped and bent straps in a exedy clutch, i just got another one...
not much help sorry

[oldcorollas]

http://toymods.net/forums/showthread.php?t=11913

It was me mate. You replied first in the thread.

/me = goldfish

hmm... the procedure you follow sounded ok in last thread

but as merc suggests, the only thing to cause weird loading on the pressure plate would be something like a spigot bearign that is not locating the front of the input shaft properly, allowing the friction plate to not have exactly concentric movement..

perhaps front bearing of gearbox could also have same issue.

non-perpendicular box or poorly located box would have the input shaft at angle, and could produce similar effect?

hmm, it always feels like vibration at high revs? does it make any difference if cluthc is in or out?
(ie, free rev to 5500 with cluthc in or clutch out and see if there is a difference?)
bent shaft could be issue.. if someone hung the box off the clutch during instal at some time?

[oldcorollas]

this is the post i was thinking of
http://toymods.net/forums/showpost.p...5&postcount=29

[thechuckster]

spigot bearing no good?

[shelldrake]

this is the post i was thinking of
http://toymods.net/forums/showpost.p...5&postcount=29

Mmmm....Thanks guys. Will inspect the carnage today...

[shelldrake]

Update time - The clutch straps which is the past have broken, are just bent. The flywheel bolts were all quite loose, except one which has sheared off in the crank. These were put in with thread locker. Spigot looks fine.

[merc-blue]

you mean ALL the flywheel bolts were loose,,
Lucky to loose the clutch before the engine (and maybe your legs)

deffently look at new flywheel bolts maybe check the the flywheel is flat/mounting square,

run a dial indicator on the back of the crank and turn the engine over by hand is there any wobble? do the same with the flywheel

[Hydra]

that isn't good at all!

Did you clean the bolts/bolt holes before using thread locker? They should not loosen like that if they are torqued up right, and are new/reusable.