Boosted Falcon

Hi Guys,
It is yet another Thankyou thread but It means a lot to me so..... Thanks a lot guys you did great ...... Now the Long form/ Story

Last weekend was a big one for Tezza Bear, Bomber, GTHOFAN, Chris (Terry son), and myself with side help and advice from Schmee. We ended up changing my clutch and pedal box manly due to the clutch being so damn heavy and cracking pedal boxes even after it had been reinforced. I ended up getting a New clutch kit including Thrust bearing, spigot, rear main seal, another pedal box #4 and sent away to Kev's Mechanical engineering lol (Schmee house) where he reinforced it for me. I also managed to get from Pheonix a 3 bolt flywheel where I took to get machined at Noble Park Brake and Clutch in Dandenong. It all went as planned and had no issues until it came to putting the 6 bolt clutch onto a 3 bolt flywheel. It was around 3pm Saturday arvo when we realised that a 6 bolt clutch was not going to mate with a 3 bolt flywheel and trying to get was hard ( you dont know these things until you pull it out). We managed to score one from Repco in Dandy, no one else had anything. Bomber and myself quickly flew down to Dandy to get it before they closed at 4pm and came back to a delicious BBQ provided by MR & MRS Tezza Bear
After the BBQ it was time to put the new clutch in. By this stage Bomber had to depart us and it left only the 4 of us. Scott did the dash while both Terry & myself and Chris played with the undercarriage components. It was going well until I noticed that the clutch fork had no movement as the bell housing was getting tightened. I always thought that it has a bit of movement and after several calls it was confirmed that it should. So we had to find out what the problem was and we noticed the pressure plate wasnt sitting flush with the flywheel and after several attempts to get it to sit flush we broke one of the bolts for the clutch plate in the flywheel. We were frazzled so we took of the flywheel and tried everything to get it out including drilling but Thanks to Kev's Mechanical eng.. he managed to drill it out and re thread it for us. Kev also showed us how to get the clutch to sit flush and we took it back and put it into practice. We first had to put the flywheel back on which is 6 bolts but ended up being only 5 after Terry showed the Horse power in his arms and believe it or not snapped one of the big mother fucker bolts. GO TERRY but apart from that everything else seemed to go well and I thought our bad luck had ended but I was wrong.
When it was time to leave Terry's, after a 18hr day under a box car, I pulled out of his driveway and everything seemed fine but it wasn't until we hit the end of the street that Scott and I heard horrible grinding noises and couldn't get 2 or 4 gear at all, 1st, 3rd, 5th worked but very noisy. At this stage I was angry and wanted to burn it but we kept going towards Bayswater as it didn't seem to get any worse. The next Morning Kev said to bring it over so he could listen to it. He drove it around the block and said gear box is fucked. I was happy to hear that it was just that and nothing else that could have caused damage to the clutch. After ringing around at wreckers and help once again from Kev we managed to find another box at Centre Road Wreckers in Clayton and fitted it. After we put the new box in we pulled the old one apart to see what happened. It ended up being the bearing cone where the Input shaft housing goes was missing causing the shaft to have movement in and out and the bearing had callapsed. Bugger but lesson learn't not to remove the housing without checking that the bearing cup and cone are there. A costly mistake.

Thanks guys for your time

That's what she said

Nice to be appreciated...........

Kev

YAY...

I been waiting to crack that one out again.

haha nice one!
Live and Learn

That was hard to read, particularly that last bit about the 'bearing cup and cone'. It is very highly documented on all the Ford forums that a 6 bolt larger clutch won't mate to an EA 3 bolt flywheel, surely you should have known this Mark You should have invited Dan around for some coffee, he would have got it sorted for you.

Good on you for having a go though lol. I wouldn't be driving around too much with only 5 bolts holding your flywheel on either, it would be all out of balance and shit which may cause issues in the not too distant future. Unless I missed the part where you fixed that

Well when it comes to Kev and cars you'll be in good hands, knows his stuff .

Can't wait till he does the work on my car

if that bloke snapped a new flywheel bolt, he is on roids. Buy a torque wrench.

If you used old bolts, well, haha. Unlucky.

Well, it's about time you have a decent gearbox in that thing. The old gearbox was a shocker. It now feels about as good as the gearbox in mine (which is probably the best T5 I've driven). The clutch is light as. I drove it last night, and it took some getting used to compared to my heavy arse clutch. Good stuff.

Damo wrote: It is very highly documented on all the Ford forums that a 6 bolt larger clutch won't mate to an EA 3 bolt flywheel, surely you should have known this Mark

yes they do... if you are willing to drill and tap the other 3 holes. i did it to mine and its been like that for 3 years so far....
(what i have is a ea flywheel with a heavy duty clutch equal to a ed xr6, 6 bolts)

good to hear yours is going well now mark.. now mine is trying to shit itself. maybe its time to slip that spare el t5 i have in. and have a look at my clutch whilst everything is off.
or it could be ive bent the fork. its the only thing i havent replaced and it was a little warped last time i put it in. and had some nasty wear on the end that lives in the pivot pin on the drivers side (i had no choice... i had to put it back in. or i had no car. havent been bothered to get another and swap them)

mark was that the clutch out of the old ea i sold you?


To fucking heavy, it was a heavy duty fucking clutch idea was for being heavy for when I was a hoon n shit, sick of fuckin em doin burnouts

Damo wrote:That was hard to read, particularly that last bit about the 'bearing cup and cone'. It is very highly documented on all the Ford forums that a 6 bolt larger clutch won't mate to an EA 3 bolt flywheel, surely you should have known this Mark You should have invited Dan around for some coffee, he would have got it sorted for you.

Good on you for having a go though lol. I wouldn't be driving around too much with only 5 bolts holding your flywheel on either, it would be all out of balance and shit which may cause issues in the not too distant future. Unless I missed the part where you fixed that

It wasn't until we pulled everything apart that we noticed that I had a 3 bolt clutch and flywheel. I even asked the previous owner if he could remember what was in it. He told me 6 bolt so I went with him. If Dan wanted to come along Im sure he would have Damo. Thanks

Frost wrote:mark was that the clutch out of the old ea i sold you?


To fucking heavy, it was a heavy duty fucking clutch idea was for being heavy for when I was a hoon n shit, sick of fuckin em doin burnouts

It was Anthony. You said it was a 6 bolt LOL. Not to worry. It was a good Heavy Duty Clutch too. Exedy Damn

Yeah you can drill and tap the EA flywheel, but in my experience not even 3 of the bolt holes will line up as the EA flywheel is a slightly smaller diameter with thicker ring gear. Also you won't have the locating dowels for the bigger clutch, better off doing it the right way IMO. I thought you converted the car to manual Mark, so you would have known it was like that I guess it was pot luck then lol.

Soo did you fix the snapped flywheel bolt in the back of the crank ?

Damo wrote:Yeah you can drill and tap the EA flywheel, but in my experience not even 3 of the bolt holes will line up as the EA flywheel is a slightly smaller diameter with thicker ring gear. Also you won't have the locating dowels for the bigger clutch, better off doing it the right way IMO. I thought you converted the car to manual Mark, so you would have known it was like that I guess it was pot luck then lol.

Soo did you fix the snapped flywheel bolt in the back of the crank ?

unless mine wasnt a ea one.... but the 3 standard holes did line up but i dont know the full history of mine so who knows if it had been converted from auto anyway.

Wow.... impressive torque setting on the crank bolt! I think they are only meant to be 60-70nm??

Its amazing how little that is really, but with new hardware and the right loctite will never some undone.

Damo wrote:Yeah you can drill and tap the EA flywheel, but in my experience not even 3 of the bolt holes will line up as the EA flywheel is a slightly smaller diameter with thicker ring gear. Also you won't have the locating dowels for the bigger clutch, better off doing it the right way IMO. I thought you converted the car to manual Mark, so you would have known it was like that I guess it was pot luck then lol.

Soo did you fix the snapped flywheel bolt in the back of the crank ?

Yer I did convert it but never took notice of what clutch it was. Didn't care either TBH. As for the Bolt in the flywheel. I was told that having 5 out of 6 will be fine so im not stressing about it. So to answer that one for you NO i didn't

Personally I would get the 6th bolt for the flywheel, it's a fairly important thing.

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markTD.... where abouts do they re-enforce the pedal box???...
ive just converted my XR 6 to a manual and I have heard stories about pedal boxes failing.
Have you got any picutres??

I dont think anyone took any pics of the pedal box.

I use a 3-4mm plate to reinforce the side of the pedal box that the pin for the clutch sits on, seems to work fine as the pedal box itself is just 1.5-2mm pressed steel they tend to crack around the pin

I also use a plate to reinforce the firewall around where the clutch cable comes thru as they also have a tendancy to crack over time yet again using a 3-4mm plate I generally use one plate on the engine bay side...Im looking into making some of these as a bolt in setup to save on welding them to the firewall

I can do a lot of general steel fabrication here at home as most people know

So send me a PM if you want your pedal box done or your firewall braced

Kev

Schmee wrote:I dont think anyone took any pics of the pedal box.

I use a 3-4mm plate to reinforce the side of the pedal box that the pin for the clutch sits on, seems to work fine as the pedal box itself is just 1.5-2mm pressed steel they tend to crack around the pin

I also use a plate to reinforce the firewall around where the clutch cable comes thru as they also have a tendancy to crack over time yet again using a 3-4mm plate I generally use one plate on the engine bay side...Im looking into making some of these as a bolt in setup to save on welding them to the firewall

I can do a lot of general steel fabrication here at home as most people know

So send me a PM if you want your pedal box done or your firewall braced

Kev

I checked out his pedal box, and it looks like you did a great job on it. The plate that Pat made up for mine is still holding up, but if I have any more trouble with mine, I'll have to take you up on your offer.

That pedal box has had a good life mark nearly 200,000km!!!!!

Cant beleive u didnt like the clutch ur not driving hard enough

Frost wrote:That pedal box has had a good life mark nearly 200,000km!!!!!

Cant beleive u didnt like the clutch ur not driving hard enough

Hahaha.
This is my 4th one in the EB now.
The one in the EA is still there.
I did like the clutch but I was getting annoyed with it cracking my pedal boxes so I went gayass standard. I made good use of the clutch though I made sure of it. Terry might have some photos of the old clutch to show you what I did

nothin suss wrote:Wow.... impressive torque setting on the crank bolt! I think they are only meant to be 60-70nm??

Its amazing how little that is really, but with new hardware and the right loctite will never some undone.

75-85 Nm

Hi fellas heres a few pics from the horrific weekend & no comment from me i was the innocent helper

tezza bear wrote:Hi fellas heres a few pics from the horrific weekend & no comment from me i was the innocent helper

Afro Clutch ????[code][/code]

It looks like a bird has made a nest on that clutch.....wtf is it???

t1MMy wrote:It looks like a bird has made a nest on that clutch.....wtf is it???

its the material the clutch disc is made out of once she over heats and is given a floggin thats what happens material turns to fur looking stuff and brakes away from the clutch disc

Wholy shit!!. I better stop dropping the clutch then.

t1MMy wrote:Wholy shit!!. I better stop dropping the clutch then.

Haha as long as it doesnt slip mate you will be fine plus clutch dumping is fun

LOL the way the day was going when we were hunting around for another 3 bolt clutch i was ready to glue the shit back onto the clutch throw it back in & send Mark on his merry way lol

No wonder he was having so much trouble. It was rooted.

How the fark mark!

likin the shot of the back yark yeah frost u will see many of those once i go manual lol!

lol that fibre shit was every where even all clogged up in the starter motor

Frost wrote:How the fark mark!

no wonder he didn't like your old clutch! haha. It was shredded!

Im sure he shredded it

Frost wrote:Im sure he shredded it

Yeah, I know. That's what I meant.

The weird thing is he never had a problem with it in the EA, but he's had nothing but problems with it in the EB.