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Old 02-01-2005, 07:17 AM   #1
R_W
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Default Some notes on a clutch change

Last weekend I replaced my slipping stock clutch (35K miles) with an Exedy Sport and Lightweight flywheel. The flywheel weighed in around 12.8 lbs, the stocker was approximately 22 lbs.

Anyway, here are a few notes that might help others, I found a lot of this here on NASIOC.

I followed the Impreza manual method, with one change. It was suggested to me to drop the TBE as a whole, and not have to replace all of the seals. If you have someone to help, I suggest this. For that you only need gasket 44022AA180.

Order two roll pins. For my '02 this is part # 051906402. He mentioned part # 905190007 for later models, so you may want to check before blindly ordering.

PB Blaster worked great to free things up removing the TBE, but the studs came out. I had ordered a full bolt set, part #'s:

Stud (3) 800910340
Nuts (5) 902370029
Bolts (2) 44059AA030

You can also get the studs at Autozone, if your counter guy can get the right thing out of the bin. Mine could not.

The instructions don't mention removing the tranny ground, but they do mention hooking it back up. This is when I realized it had been snapped off at the tranny. I read that on the forums, and promptly forgot it. You should disconnect it here:



***EDIT*** 5/Feb/05 After 45 miles of driving, last night my wife started the car and threw a missfire CEL. This is likely due to the flywheel. This flywheel was not supposed to be light enough to do that so I'll watch it and post back the results ***EDIT***
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Last edited by R_W; 02-05-2005 at 09:51 AM.
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Old 02-01-2005, 07:36 AM   #2
thrdeye
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A few questions, as I think mine may be on the way out as well.

How much experience do you have with clutches/How hard was your install on a scale of 1-10?

Any CEL due to flywheel?
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Old 02-01-2005, 08:59 AM   #3
R_W
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The only other experience I have with clutches is replacing a transmission on a '64 Chevy Pickup. I have done quite a bit of other mechanical work over the years.

On a scale of 1-10 for hard, I would rate it a 7, maybe? It was much more time consuming than anything else. You learn alot about the car, because you take off alot of stuff. Other than my wife helping me drop the TBE, and "standing in wait" while I pulled back the transmission in case I dropped it on my head, I did it all alone. A mechanically inclined friend would certainly speed things up. It took me two full days.

The more experienced will laugh, but the most difficult thing for me was disconnecting the front axles. You have to disconnect the front ball joint. There were no specific instructions, and I had no experience at it. In the end I used a pickle fork and cheater bar to prize it open.

No CEL's with the flywheel. It is a little more difficult on 1st gear takeoff (but no shudder), and a whole lot easier to double clutch. I haven't ridden with the wife yet, so we'll see what kind of damage that may cause...

***EDIT*** 5/Feb/05 After 45 miles of driving, last night my wife started the car and threw a missfire CEL. This is likely due to the flywheel. This flywheel was not supposed to be light enough to do that so I'll watch it and post back the results ***EDIT***

Last edited by R_W; 02-05-2005 at 09:52 AM.
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Old 02-01-2005, 11:47 AM   #4
vvk
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Impreza GC8 No need to disconnect ball joints

Thanks a lot for posting this, definitely useful tips!

I just wanted to add that there is no need to disconnect ball joints when removing the axles. This has been discussed in the past, so search and you shall find.
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Old 02-01-2005, 11:57 AM   #5
R_W
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Tell me it's not so...I'll search longer next time!
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Old 02-01-2005, 01:12 PM   #6
vvk
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Impreza GC8 example

Quote:
Originally Posted by R_W
Tell me it's not so...I'll search longer next time!


For example, this thread:

http://forums.nasioc.com/forums/showthread.php?t=211436

Just mark the tie rod thread, turn it until it unscrews, remove strut bolts and you are done. If you mark everything well, you should not screw up your alignment.
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Old 02-01-2005, 10:47 PM   #7
Pakin
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I'm not sure how you removed the ball joints, did you unscrew the nut with the cotter pin or did you undo the 14mm bolt on top?

-paK +1
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Old 02-02-2005, 07:23 AM   #8
R_W
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The 14mm bolt on top. It should be the one that the head is facing the front of the car.

Robert
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Old 02-02-2005, 11:17 PM   #9
Pakin
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Quote:
Originally Posted by vvk

Just mark the tie rod thread, turn it until it unscrews, remove strut bolts and you are done. If you mark everything well, you should not screw up your alignment.
Hmm, interesting.

But from just that information, it seems to be more work involved compared to removing ball joints and DOJ.

-paK +2
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Old 02-03-2005, 05:26 PM   #10
vrg3
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Couldn't you just remove the two big bolts holding the strut to the hub instead? If you mark the position of the upper one you can maintain your camber setting. That's what I did when changing the axles on my 93 Legacy.
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Old 02-03-2005, 06:11 PM   #11
ImprezaVA
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Quote:
I pulled back the transmission in case I dropped it on my head
When I first read that I thought you said you dropped it on your head .......

Thanks for the useful tips.

-Charles-
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Old 02-03-2005, 06:47 PM   #12
R_W
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Quote:
Originally Posted by ImprezaVA
When I first read that I thought you said you dropped it on your head .......

Thanks for the useful tips.

-Charles-
The damage would not have been noticable...
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Old 02-05-2005, 09:53 AM   #13
R_W
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Threw a Missfire CEL after 45 miles. Happened on startup. I'll watch it to see if it happens again and post back here.

This is most likely caused by the flywheel, but from what I read this one was not light enough to cause the problem.

RW
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Old 02-05-2005, 05:32 PM   #14
quazimoto
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I have the Act Streetlight flywheel(14lbs) and threw a misfire right around 150 miles.I reset the ECU and am now at 400 miles with no CEL.I reset the CEL with my Accessport as apposed to a battery disconnect.Don't know if that makes a difference.
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Old 10-14-2007, 07:15 PM   #15
Marc5000
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it's most likely P0301,2,3 or 4 or all 4... it's engine misfire in cyl #__ .. it is caused by the flywheel.. but with the accessport.. if you go to a place that can tune accessport.. they can disable the CEL's for those codes.. thats what i had to do.. i have the ACT Streetlite 13.9lb
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Old 10-16-2007, 05:13 AM   #16
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Old 10-16-2007, 03:43 PM   #17
juztin180
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Quote:
Originally Posted by prometheum View Post
exactly what I needed to run across today. THANKS!!!
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Old 08-03-2009, 10:42 PM   #18
johnpaulm1208
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thanks for the write up! definatly needed this for my upcoming clutch swap.
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