Davie's Activa Clutch

[elma]

I'll read the whole thread, I think I missed a fair bit here.

[CitroJim]

James, I hope you enjoy the thread all the way through... It's quite a tale and it shows how much easier a 1.9TD/BE3 clutch is to do!!!

Excellent progress today though, it's amazing how a bit of sunshine makes everything better...



Gearbox is now split from the engine (after finding the hidden bellhousing bolt - again It gets me very time...) and we see a classic release bearing pull-out... New clutch is ready to go in after I've jumped on the lathe and made up a special stubby alignment tool...

With the gearbox in that position there is just room to do the job with the aforementioned stubby alignment tool...



In the picture you can just see the release bearing on the guide tube rather than where it should be - clipped into the clutch diaphragm spring...

Lunchtime now, will continue later...

[daviemck2006]

Good work Jim. I'll bet the bugger of a bolt kept jumping about too!

[CitroJim]

Good work Jim. I'll bet the bugger of a bolt kept jumping about too!

Yes, the bloody thing kept finding new places to hide!!!!

[superloopy]

I can't believe that's enough space to fit a clutch Jim.

Is that the clutch plate on the flywheel to the left then if the bearing is, as you say, on the guide tube?

I'm learning i think!

[xantos]

I can't believe either that someone can change a clutch like that...

But sir Jim is probably so tinny he can fit in the gearbox to tighten the clutch in place

[CitroJim]

The clutch failed because the release bearing seized up and every time the clutch was disengaged a massive strain was put on the C Clip that holds the release bearing into the diaphragm spring.. Over time it heated up very severely (which you can see in the pictures) and failed. You can see how distorted, how hot it's been and how bent it is.. Amazed it didn't make a racket...



The clutch itself is OK...



These are the ropes now holding the gearbox secure whilst the crane, which does get in the way, is out of the way...

I can't believe that's enough space to fit a clutch Jim.

I can't believe either that someone can change a clutch like that...

But sir Jim is probably so tinny he can fit in the gearbox to tighten the clutch in place

Well, believe me, you can! This is the Team WFA method and it has been done twice in the past like this... It is a bit fiddly but it's a lot easier than trying to remove the gearbox with the engine in place - that is a very difficult task indeed.

I did need to disconnect the gear selector cables and found the easiest way was to disconnect the ball-ends and then remove the place holding the cables onto the back of the gearbox complete - saved fiddling around with the cable retaining clips...

Is that the clutch plate on the flywheel to the left then if the bearing is, as you say, on the guide tube?

Yes, that's the flywheel and clutch cover on the left...

I'm learning i think!

That's excellent Mike

That's all for today... Off to have a shower now and fix the workshop radio which packed up this afternoon. I then need to fix my stereo tuner in the living room which also packed up shortly afterward

[CitroJim]

Interestingly, the old clutch is a LUK and the new one going in is also a LUK

Pretty certain it's the original clutch too...

[daviemck2006]

There was absolutely no warning of it going. It was smooth, no noises vibration. Just clutch in, away to pull out of a junction when it went. I was only 1 mile from home so started it in gear and the box is so smooth clutchless changes were no problem. I could have driven it all the way to Jims without the clutch if I had had to! Here's hoping the replacement sees another 128000 miles [GRINNING FACE WITH SMILING EYES]

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[superloopy]

Interestingly, the old clutch is a LUK and the new one going in is also a LUK

Pretty certain it's the original clutch too...

LUK is specified as oem on service.citroen although i'd always look for Valeo myself (what am I talking about )

I know it's a no-goer but if the original clutch was found to be ok would it be possible to just replace the release bearing?

What's that gizmo you've got coat-hangered to the earthplate on the wing?

[CitroJim]

Davie, judging by the state of the bearing, new and old shown for comparison in the picture below, I'd have expected some odd noise and odd feeling but your experience is the same as all the others that have gone like this - absolutely no warning at all...

This is the first time I've seen one that has gone so I can't comment if all other failures of this nature were caused by the bearing seizing...



I'm sure it'll be good for another 130,000 miles now Davie!

What's that gizmo you've got coat-hangered to the earthplate on the wing?

That's the clutch slave cylinder Mike, tied up out of the way with a bit of steel wire saved from when i last terminated an armoured mains cable... I find it useful for all kinds of things. Another length is supporting the disc calliper on the Nearside...

[daviemck2006]

It's only done about 500 miles since I got it home, and as Chris is as surprised as the failure I'm assuming that it had shown no deterioration at all. The next 500 miles will be easy on a clutch. Basically on to motorway, 70mph for a few hours then Aberdeen and 42 miles of windy roads activa style [emoji23]

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[CitroJim]

That's exactly how they go though Davie, suddenly and without warning!

[daviemck2006]

You should measure the thickness of the friction material old and new. Looking at the photos it looks like very little difference.

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[CitroJim]

You should measure the thickness of the friction material old and new. Looking at the photos it looks like very little difference.

Quite a lot actually Davie..

New: 7.8mm

Old: 6.3mm