clutch replacement

[surfingdrums]

I'm replacing the clutch in my zenki SR5. only problem is, I don't see how the tranny comes off. I got the whole shifter nonsense off and out, but now just have a hole in the floor of my car...and...that's about it. if ANYONE can help out with a writeup, or some pictures...anything will be appreciated. even smart-ass comments will be taken into consideration seriously though. I'm trying to get this done this weekend. I promise I'll do a write up of it when I'm done (with pics) if anyone helps me. thank you x1000 in advance

Matt

P.s. sorry if it doesn't make sense. I'm quite tired from work and trying to figure out how to pull the transmission...

[Ivan141]

Dude... you seriously need to download the tech manuals! Will help you not get stuck with these problems.
You need to remove the propshaft, then unbolt the bellhousing from the engine (make sure the tranny is supported, some people tie a rope around it from inside the car.. might be an idea). Also dont forget to unhook the slave cilinder and speedo drive.
Once all is loose you can pull the gearbox back and out, exposing the clutch so you can work on it.

[Mux213]

Don't forget to first drain the gearbox oil before you do all that ivan sais.

Haven't done this on the hachi so not 100% sure but I forgot to do this when I took the gearbox out of the RX7 and when I got it off the oil nicely ran out of the bit where the propshaft used to be : D

Anyways, just what ivan sais, unhook everything around the gearbox: speedo cable (just unscrew) and clutch slave thingy (two bolts and it comes off, check Banpei's project thread for pictures), then remove propshaft, then unbolt the tranny from the engine.

This is one job you really wanne do when the car is raised (you can do it when you have the car on jack stands but is alot harder) and with the help of a friend. If you do it with jack stands, you can also support the tranny with a good floor jack.

*edit*, owh and undoing the shifter aint a total loss of time, you don't need to remove it completely but there are a few bolts that need to come off, allthough not entirely sure how this is on the hachi, like I said, I've only removed the tranny on my rx7

[surfingdrums]

where can one download the tech manuals? the the factory service manual? Hachilife.com used to have it on their website but dissappeared somehow.

[Mux213]

Check the technical FAQ in this very same forum , there are download links to the PDFs of the manuals in there

[surfingdrums]

well I'm finally done and documented everything quite well. I would be willing to do a write up with pictures if it is wanted. let me know

[Ivan141]

You're more than welcome to make a write-up on clutch replacement. If it's good we can use it on the aeu86 homepage in some form or other..

[surfingdrums]

So before you begin you are going to want the following

TONS of rags
a good 1/2in AND 3/8in rachet set. (trust me on the half inch stuff. these bolts don't want to come off and I snapped 3 extensions)
plastic bag
masking tape
jack
jack stands/ramps
space
time
help is always useful

firstly take out your shift bezel and remove your shift knob, boot, then shifter. you should now look like this:


now put tape over that hole so you don't get any crud in your gear oil.

There are 4 bolts holding the driveshaft to the differential you need to remove. After they are out, your driveshaft may be still stuck in place. I just tapped mine gently with a hammer 2 or 3 times and it came loose. just pull it out of the tailpiece of your transmission and it will just fall out

Diff side(lean your head to the right to see it clearly):


Tranny side(lean your head to the right again):


You will now need to put a plastic bag over your tailpiece and tape it on there so you aren't rolling around in 100weight the rest of the project.

Next remove your clutch slave cylinder:


just let it hang after it's off.
Next is the most time consuming part of the project. There are 6 or 7 bolts holding the transmission to the engine block. One holds the starter bracket in place. These bolts WILL be stuck and this is what the 1/2 inch drive sockets are for.
After you get all the bolts holding the tranny to the engine block you will need to take off the tranny mounting bracket, disconnect your speedo cable, and remove two sensor(?) wires.
Before

After (speedo cable on right)


After this I had to remove the downpipe (exhaust pipe piece between header and catalytic converter) to drop it down out of there.
To drop your tranny, put it on your jack with wheels and lower it as you pull it towards the rear of the car. CAUTION!!! it will be leaking oil!!!

Your clutch is now exposed.


Just remove a few bolts from the pressure plate and then pull it off of the pins which will reveal your friction plate.

Pull your friction plate off and all that will be left is your flywheel.

You can (should) remove your flywheel and have it resurfaced before putting everything back together.

Hope it was helpful...pm or email me if anything is wrong or needs to be changed!

Matt

[Mux213]

Matt, great writeup man!!

We'll be moving that one to the how to's on the front page soon

[banpei]

Whenever we get the new front page working