NA8 lightened flywheel and clutch install

[fastfreddygassit]

The black beast has finally had a new clutch fitted.
The clutch kit is an Exedy that was originally purchased from flyinmiata.com.

I though that if I am going to all the trouble of replacing the clutch, I may as well change the flywheel.
So, to that end, I purchased a Toda 4.5kg racing lightweight, one piece CrMo flywheel.

Another reason for replacing the flywheel is that I was pretty sure my original flywheel
would need to be machined and I wanted to do the install in a day. So machining the original was not an option.
I wasn't wrong about the original needing machining!! (original on the right, Toda on the left)


Gratuitous shot of my new front lip spoiler under the pretense of showing the clutch kit


The actual removal and install took from about 11:30ish am to about 9pm.
It didn't help that I wasn't fully prepared and failed to purchase/bring loctite, gearbox oil and high temp grease.
I had printed out the various instructions from miatanet and photocopied the relevant pages from
the Keith Tanner book and the enthusiasts workshop manual but in the end we all still did it ad-lib
I couldn't do this by myself so had some great (and much appreciated) help from meanmx (the artist formerly known as Ben ),
Greencomet (Mr. zero offset), Stu (stainless muffler man),
Clubsport Joe, and coffees were supplied by a nameless female companion.

greencomet and fastfreddy wondering which way the gearbox goes in

The actual install was completed at my parents place because they have a pit. It would have been a
pain in the ass to do it on axle stands.

Gearbox lying forlornly on pit floor.

[fastfreddygassit]

My thoughts on doing this job (I am sure the others will post their impressions):
1. Next time I will possibly pay someone to do it
what a pain in the ass job.
2. Remove the ENTIRE exhaust system. It just makes it sooo much easier.
3. If possible, use a pit or a hoist.
4. The gearbox is not heavy. reading the literature, I was expecting it to weigh much much more than it did. It feels less than 50kg??
5. Use gloves. (another item I sort of forgot )
6. Have plenty of heavy duty handcleaner around. You don't want to get grease on the clutch.
7. Have a HUUUGE supply of globes for the workshop light. I went through 7 or 8 I think??
8. make sure all the brackets are out of the way when re-installing gearbox.
Even when I thought I had them all out of the way, one still was tucked in.
9. There are 11 bolts (on the NA8) holding the gearbox in. And number 11 is a prick to find
10. Have a decent collection of extension bars, flexi-joints, knuckle joints and a breaker bar and some sort of impact gun.
I used a battery impact gun cos I couldn't be stuffed bringing my compressor and rattle gun to M&D's place.
11. fit and tighten both a top bolt and a diagonally opposite bottom bolt before checking clutch operation.
I pulled the gearbox out again because I thought I had fitted the new thrust bearing the wrong way, when
it was only that the top of the gearbox was still 20mm away from the motor

It is not a technically difficult job but it was physically demanding due to the inordinate amount of time I spent
holding the f*%king gearbox up whilst trying to line it up and remove obstructing brackets and such.

But it is all done
How does the car drive now?
1. I can spin the wheel off the line now. Not that is something I usually do, but my previous clutch would just slip.
2. Take up point is much much better.
3. I can floor it in any gear without the \"torque convertor\" effect of a slipping clutch
4. The lightened flywheel is interesting. Combined with the new clutch I have stalled the car a few times
When changing gears, the revs drop off big time which is really cool.
The car revs out much better than before but it is not as \"sweet\" as the NA6.
Dunno, the jury is still out of the flywheel. I like it, but I have to get used to it before I can give a definite impression.
Ben likened the new set-up as halfway between my original set-up and his car (NA6).

[green_comet]

Was awesome fun yesterday Mike..

Im glad that it all worked out good.

[CT]

Nice work boys. It's not a hard job but it can be tedious. I've done 3 now on axle stands - it sucked every time. Pits FTW!

[meanmx]

One other tip. If you are doing this in a pit move the bucket of oil out of the way. The amount of sh*t Fastfreddy dropped in there was extremely comical. Especially when the cordless impact gun went in

Ben

[green_comet]

Especially when the cordless impact gun went in

Ohhhh crap, I missed it. I was there when one of the ppf bolts went in.

[ampz]

9. There are 11 bolts (on the NA8) holding the gearbox in. And number 11 is a prick to find

Yes

Breaking apart Mr Q's green car on stands...

His son needed to be dragged away because of the profanities coming from his car!

[fastfreddygassit]

yeah, THOSE buckets of oil.
You would have though after the first dozen or so bolts that I dropped into it, I would have moved them.
Actually, I thought looking for the 6 clutch washers that I dropped in the sawdust was pretty funny....NOT!
If I didn't have the sh!t hot mechanics magnet, I would have been up the proverbial creek.
Actually, dropping the impact drill in the oil was sort of funny.
I was in the pit pulling the car back when SPLASH! There is oil all over me.
I look to see what caused it and yes, it was a brand new impact drill.
Ya gotta laugh sometimes.

Some more pics:
Fastfreddy looking really happy. Have no idea why.
Maybe it is because I am using a pit instead of lying on my back under axle stands..


the clutch in place. Note the totally indispensable clutch alignment tool.
Don't attempt this without one.

[pcmx5]

Well done Michael,obviously far more talent and patience than me!

I got a new exedy heavy duty clutch put in when they put the 6 speed in so I chickened out on doing it myself.

All up cost was $900 to fit the gearbox, machine flywheel, supply and install the clutch kit, including a new spigot bearing and gearbox oil, which I didn't think was unreasonable.

We must catch up for an early morning blat down the GOR so we can do a comparison.

You, like me, must surely be finished mods by now?

Peter

[Boags]

You, like me, must surely be finished mods by now?

[Fatty]

You, like me, must surely be finished mods by now?

pfffffft, he hasn't even got a turbo yet! still HEAPS of mods to come i reckon !!

[meanmx]

He's satisfied temporarily at the moment because he can beat me off the line now. But wait until the turbo, then the fun will begin again

Ben

[Fatty]

He's satisfied temporarily at the moment because he can beat me off the line now. But wait until the turbo, then the fun will begin again

Ben

is this true fastfreddy? you're satisfied??

next time that feeling of satisfaction washes over you, just think back to our little joust at the traffic lights in geelong....

[Craig]

The actual install was completed at my parents place because they have a pit.

Nice to see they finally let you out of it after puberty!

[green_comet]

Are you happy with the mod Freddy? You seemed to be on Par with the Striped, Offset Machine..

Im looking at getting a Fidanza after I sell my Zoom console.

I was quite shocked actually that you didnt leave me for dead.. There must be more to my car than meets the eye..