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Clutch Replacement, 94 cs turbo..
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Posted by Yaofeng [Email] (more from Yaofeng) on Fri, 19 Mar 2004 08:15:43 Share Post by Email
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This is to update my project removing the drivetrain to replace the clutch. Faced with another business trip this coming Sunday, I have to get things in order before I leave. So I was working over time after coming home the past two nights until midnight.

I ordered the valve cover gaskets from Eeuropeparts along with the torx screw on the s-belt tensioner bracket which I stripped trying to remove. The counter-sunk screw is exactly the same as that on the wheel. Extracting it was not too difficult. Although I have to get a set of Cobalt bits from Home Depot. They are really good cutting metal.

Removed the sump pan and timing chain cover. Both the timing chain and balance shaft chain, gears, guides and tensioner are in very good shape. So I quickly buttoned them up and lowered the engine from the stand to install the clutch.

As some of you may know, the 9k transmission is massive. Mating the transmission to the engine is not easy. You will be aligning the transmission input shaft to the engine and the differential to the intermediate shaft at the same time. After a couple of failed attempts, I found I didn't put the 5 speed transmission in neutral. So the shaft won't turn as it is being lined up. After putting it in neutral, I succeeded the next try.

After attaching the ancillaries to the engine, the next big task is to lift the drivetrain back into place. The picture shows the contraption I use to coach the drivetrain into the engine compartment. Working alone in my garage, the picture was taken around midnight last night. The 9k engine is slanted 23 degrees forward. So I used a come-along in conjunction with the lift. The come-along is hooked up to the rear engine mount bracket to tilt the engine. Pin point control is not an understatement with these tools.

posted by 165.254....

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