Gearbox Removal

[PeteGLi]

When removing, and re-installing the gearbox (on a 1.8 inj DX engine code), does the flywheel have to be in a specific position in order to separate the gearbox easily from the engine block?

On my old I.6 FR engine, the flywheel had a cutout which allowed the inboard driveshaft flange to slip over it, but the 1.8 flywheel doesn't.

I did get the gearbox off eventually, but I had to j....j....j....jiggle it a bit, Granville.

Obviously, I would rather it slides back on with a lot less effort than it took to get it off.

Also, should the clutch friction plate be the same size as the clutch pressure plate. My pressure plate is 210mm, but the friction plate is smaller at 200mm.

[markh]

When i changed the clutch on my GTX a couple of weeks ago, i didnt need to have the flywheel in any particular position to get the box out. It was relatively easy to get back in (apart from the weight of the bloody thing !), you obviously need to make sure the friction plate is central, and that the gearbox is in gear, then just jiggle the thing about until it slides in place. I fitted an LUK clutch kit, and im sure the friction plate was exactly the same diameter as the pressure plate.

[PeteGLi]

Cheers Mark,
It is a LUK clutch I have on there.
I will check the new LUK clutch kit before I hand over any cash !
If the new friction plate is 210mm, then I may need a new flywheel as the smaller friction plate seems to have worn the biting surface of the flywheel.

[PeteGLi]

Looks like someone fitted the wrong size friction plate at some time in the past. In the new clutch kit both pressure and friction plates are the same size!

Anyone know if it is possible to get the biting surface of the flywheel machined flat again, or do I need to get a new flywheel?

[markh]

Pretty sure they can be machined Pete, obviously depending how much material needs to be removed to give a good mating face.

[MikeH]

You can get flywheels machined, but it's probably not worth it, unless you get mates rates at a machine shop.