[roxydog01]

Two years ago today,I replaced the original factory clutch,which was worn out,with an Excedy standard duty one.

Today the clutch is suddenly very soft and is making all sorts of sounds when you push the pedal in.
Throw out and/or spigot bearing most likely.

I have done less than 2000k on this clutch and no towing.
No doubt I will have to take it out and have a look at it to see whats wrong,however I have a few queries:-

Did I get the right clutch(standard) or should I have gone Heavy Duty?
(Tire size is 215 75 15 BFG All Terrains on Three spoke alloy factory rims.)

Since its only two years since I had it renewed,would I have to get the flywheel machined again?
This was done when the clutch was done as a matter of warranty.

Any and all help much appreciated,thankyou.

[Gwagensteve]

Was the throw out and/or spigot bearing replaced last time the clutch was done?
Might be no need to replace the clutch, just the bearing(s)

[roxydog01]

Yes they were,both of them were in the clutch kit.

[bumstein]

Pull it apart and see. Might just be the thrust bearing or something stuffed (although light/soft feel on the pedal makes me think the pressure plate springs are stuffed). I don’t think much of the Exedy clutches myself but no way it should fail in that time/km’s IMO.

[sideways]

Mine did something that sounds pretty similar. The dumshit mechanic didn't install the clips that hold he thrust bearing to the clutch fork and it rotated out of place. This created a whole bunch of play in the pedal and it made all sorts of horrible sounds when it got to the bottom. The clutch fork was rubbing on the back of the thrust bearing which spun with the clutch.

[roxydog01]

Bumstein,if not an exedy brand clutch,which should I look for?
Should I get a heavy duty version or stay with the standard?

[bumstein]

I get factory standard ones from Japan, the stock clutch is actually pretty good I reckon and are well and truly good for the purpose unless you’re running a motor with heaps more power and huge tyres.

I’ve ordered a few from LROR in the US, or Megazip straight from Japan. Others may have good results from other brands. Although I don’t rate Exedy myself, please DON’T use Repco branded clutches.

If you’re considering LROR the shipping can be very pricey. Look into Shopmate, Australia Post ship it here from the US. LROR has free ground shipping so it goes to a Shopright address in the US, then you pay Aus Post to bring it here.

Megazip works a treat, allow 3 weeks from ordering to get your stuff though. Have no idea how it compares in price to ordering it through a dealer or similar (if you still can) but a few options to look at.

[pete_79]

bumstein wrote:

Megazip works a treat, allow 3 weeks from ordering to get your stuff though. Have no idea how it compares in price to ordering it through a dealer or similar (if you still can) but a few options to look at.

My fuel pump was considerably cheaper through Megazip then the local dealer.
But that’s heaps smaller and lighter then a clutch, freight cost could make the prices closer for that sized part.

[bumstein]

Just having a quick look, Megazip is around 170 US clams for the clutch. 34.50 for a thrust bearing if you need one. Shipping isn't normally too bad from Japan, worth a look I reckon.

[roxydog01]

got the thrust bearing replaced,clutch was fine.
Now their is a lot of play/slop in the gear lever!
Its so bad I cant get 3rd or 5th gear at all!

Is a part missing from where the gear lever goes in,as that what it feels like?

What else wouls cause this?

[Technotron101]

I know the sierras have an issue with the shifter bush disintegrating which causes the issue you're describing, but I'm not sure which vehicle we're talking about here... I'm assuming jimny, based on your profile?

[roxydog01]

yep 2002 jimny.
Bush is fine,problem feels to be lower down as if a part is missing form between tip of gear lever and everything else.

[alien]

My last 2 clutches have been out of wrecked low-km jimnys! The first one only "died" because the rear main leaked and the clutch got wet.. current one had 30,000km in the jimny it was in, and had been in my sierra for well over 5 years, maybe closer to 7 or 8? That with 31" tyres, 1.6L engine and a heavy right foot too.

I didn't realise megazip was so cheap for a clutch and will definitely go factory again!

[roxydog01]

Found the problem! Plastic bush the goes onto the bottom of the gear lever had come up and jammed into the slots for 3rd and 5th gear.
Put bush back into proper position,reinstalled gear lever,now have a complete set of gears again.

This is why i HATE others working on my zook!