G16 Swap Done - Clutch Problems

[Hybrid]

I swapped a G16A into my 1.3 91 WT sierra on the weekend. I thought I may as well do the clutch at the same time. So went to Autobarn for the clutch. Was given what I was told was the right one and didn't think anything of it. So I went to mount it and of course the spline count on the disk was wrong. I thought well at least I can use the pressure plate which looks to be the same with my old clutch plate. So mounted that up no problems then when it came to putting the clutch throwout bearing in it didn't fit either. I hadn't thought of this and once again assumed because the pressure plate appeared the same the old throwout would be fine too. Now its all back together the clutch isn't entirely engaging. It takes of pretty soft and if I blip the throttle it slips.

My questions

1. Is this because I've used the new pressure plate with the old clutch plate and throwout?

2. Could it be something to do with the set up of the G16A adapter. I used BenT's adapter.

3. Is it possible to take out the jack shaft, unbolt the transmission and slide it back enough to put my old clutch back in?

I should have known better than to just accept what somebody gave me over the counter.

Cheers,

John

[dank]

mate you are making life way too hard for yourself...you should just take the whole thing back to the auto shop and ask for the proper one. You've paid the money you should have got the right product. If you are using the sierra gearbox you should be using a sierra clutch not a vitara gearbox clutch. This MIGHT be your issue. Otherwise take in as much detail to them about your car and try and match it up to the right product on their books. It could also be something to do with the extra space that the adapter has caused that might be making it slip...but i'm justr speculating....someone will reply soon who has done it.

good luck! and far out ANOTHER g16 conversion! i wonder if there are any vitaras and balenos left with engines in AUS?

[me217]

wen i did this conversion i bought a new exedy clutch and when i went to order it they asked me if i had a 18 or 20 spline gearbox so i had to pull the old engine out and split the engine and box to count the spline. turned out i had 20 spline. which actually had a more expensive clutch just my luck. anyway just count the spline and go back in and they should give you the right one.

me217

[Hybrid]

Yeah guys. Mine is the 20 spline and he gave me the 18 spline. The reason I didn't take it back was because they were closed on last Friday and I had to have the g16 in that night so I still had enough time to get the injection sorted.

I thought more about the adapter causing the problem due to spacing. If it was the adapter you would think my problem would be getting it to disengage not the other way round. The box would be spaced off the flywheel the depth of the adapter therefore technically the throwout would be further away from the pressure plate. All this should mean though is adjusting the clutch cable to make up for the extra spacing. There is a bit of play in the clutch lever which, I would have thought, means that the throwout isn't pushing on the pressure plate when the box is mounted. That would have explained the slipping nicely . My last guess is something happening between the old clutch and new pressure plate.

The rush was to get it ready for a Fraser trip tomorrow. Its starting to look like it was all in vain.

[BenT]

There are also two types of flywheel on a G13 depending on the year. One is flat, and the other has a step between the pressure plate mounting surface and the friction surface of about 2mm.

I bet you have the wrong pressure plate for your flywheel.

The exedy catalogue has some good info on the different clutches available. http://www.exedy.com.au/catalogue.htm

Ben

[Hybrid]

Ben, Thanks mate. That sounds about spot on. I'll check them out tonight. the 16 I've got came in a suzi already though with a rough home made adapter. So the clutch flywheel and plate for that are sitting there. I'll put them side by side and see what I can come up with.

Cheers,

John

[matsmad]

I bought a daikin clutch from cheapa auto spares. There are two types of flywheels, and two types of thrust bearings also. Im lucky I just got the right one first time.