Zane Clutch.

Spider Wales

Spider Wales

Hero member
Location
Newport South Wales
O/K, Clutch is out, one broken plate at the back but no other signs of damage.
However, the clutch basket has about 1mm of play, (rotational) and about 1mm of play laterally on the main drive gear. It was bloody cold outside when I took it apart and as it is an alloy basket on a steel gear, the question I ask is, "is this within tolerance?" or would expansion when it's hot close this up to almost nothing, I have nothing to compare it too.
I also can't see from any picture of what the drive transference method between the gear and the basket is, (some form of spline? it can't be just the few alloy rivets, can it?)
There is also play in the front balance weight on the outside of the balancer shaft, primary side, about 1mm again rotationally) but as of yet I have not checked under the alternator for more play on the other side.
The clutch plates measure within spec, (a little worn, but it's had a few owners, so I have no idea of what heavy handedness it's had in the last 12000 miles or so) and the 916 springs will fit, but are about 1.5mm longer than the spec in the manual.
Opinions please gents? (No doom gloom and despondency please Piet  ;))
Dave
 
Dave,

Never had a basket open, reckon there's cush drive rubbers inside.  The play does sound excessive though, don't think heating the components will take up 1mm. Seems a washer or 2 may be missing from the mainshaft....   Might be better to search for a replacement basket.  

Check the longer springs don't coil bind when the clutch is fully disengaged.  

Broken plates are quite common, still not sure what exactly causes it.

Play in the balancer shaft?  Do you mean play between the gears or between the bobweight and shaft?  There is a slight design fault in the bobweight fixing..... the central nut bears on the abutment of the shaft only and the bobweight is held by the 3 tiny screws.  These will work themselves loose after a while.  Cure is to machine the shaft so the bobweight sits slightly proud, maybe 0.1-0.2mm, the central nut will now take the brunt of keeping the bobweight in its' place.  Engine needs to be torn down completely for this.

Hope that's not too much doom gloom! :D

piet
 
Eeeee, where's my rusty razorblade, Lol, thanks Piet, it's the bob weight loose on the shaft,What do you think of shimming it till it's tight? I don't want to pull it all apart just yet!
 
Shimming will do the trick for the time being, Dave.
Replace the 3 screws while you're at it... they're probably already knackered.  Use loctite on them as well as on the central nut.

piet

 
I was actually talking about the other side Piet, but thanks for the advice, I had a ganders at the Manual/Parts book and understand what you mean. I will probably shim both sides for now, but I cant see any reason as to why I cant remove all the gears etc from the balancer shaft, take out the big circlip holding the big bearing and drift it out using the shaft, right to left.......unless I am missing something!
WSY?
Dave
 
Dave,

Slight correction.... had a long look at one today, Roger had it in bits, needed the same mod.

It is the gear that is held on by the screws, the bobweight is actually quite a tight press fit on the shaft and shouldn't work loose.  Due to the irregular forces on the gear, the 3 M6 screws soon give up and given time, the gear will shear the screws completely, letting the screw heads to merrily fly around inside the primary drive housing......

The shaft can be pulled with the engine in situ, but it's a royal pain in the arse to get it all assembled, you will need a gigantic C-clamp or similar to get the bobweights back on the shaft.

piet
(still don't like 'em)
 
Like them you may not, understand them? well it looks to me like you most certainly do!.
My loose Bob weight is on the Left, (Primary) side, you are geting your sides mixed up, the three set screws are on the other, (alternator) side, this is the side I haven't examined yet, but have every intention of doing so, ref the three screws!.
The weekend is on it's way and not forsaking the Family, I intend to tear it apart a bit more. I will keep you all informed of my findings!.
Dave :D
 
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