Thanks to Alex and Stephen (xn00dlesx) for showing up and helping. Here are some pics: http://www.briangt.com/gallery/sti-clutch (replaced with new OEM parts) old one was pretty dead -- Brian
Thanks for this... I hope I won't need to do it anytime soon, though I fear that *something* was slipping the other morning when it was cold; hopefully just the tires!
It slipped in 6th first at around 3.5-4k, and then worked it's way down to slipping 3rd gear over time. It first started slipping a month ago. We got the parts from www.subarugenuineparts.com, which is ~27% off retail prices, and you don't have to pay sales tax. Part prices: Clutch disc: $95.12 Pressure plate: $127.36 Flywheel: 179.65 Release bearing: $100.58 I was originally going to get the flywheel resurfaced, but decided to just get a new one. I didn't want to have to wait for a weekday to find a shop to resurface it. The new pilot bearing wasn't needed either, as the original one was still up to the specifications in the service manual. I am going to get the flywheel pressure plate resurfaced for the next time the clutch goes out This one lasted 2 years and 34k miles. -- Brian
so I'm going to guess this is more than one person could handle correct? Thanks for the pics. They'll help when I replace mine.
Brief description for 05+ STi: Here is the setup that you can do by yourself: -remove IC -remove engine pitch mount -remove starter -remove clutch slave -remove clutch release pin, lifting fork out of release bearing -disconnect wiring harness connectors near pitch mount for diff (3 connectors) -lift car -remove bottom part of steering joint and lift allow room to store the starter to sit while dropping tranny -remove full TBE -drain tranny -remove diff protector plate (6 bolts) -remove propeller shaft (4 bolts + 2 for mount) -cover propeller shaft point on tranny -remove front wheels -disconnect swaybar endlinks from control arms -remove bolts holding abs cables and brake lines to struts (4 bolts) -undo front strut attachments from hubs you need help for this portion: -disconnect lower ball bolts, lift hubs from ball joint, pull axle splines from transmission, push axles aside, and put hubs back on ball joints (need help for this step) [2 people] -put jack under transmission, and remove 6 - bolts holding the mount to the chassis -remove bolts connecting tranny to engine -push tranny counterclockwise to give room to remove shift linkage and reverse cable -lower transmission from car [2 people] -swap flywheel, clutch, pressure plate [extra person to hold flywheel in place while torquing needed here] -install release bearing, release pin and configure clutch fork on the tranny -lift tranny back against the engine (there are 2 studs to assist) [3 people] -bolt tranny to engine -install 6 bolts to hold tranny mount to chassis -disconnect lower ball joint, lift hub from ball joint, put axle splines back into tranmission, put hub back on ball joint [2 people] Then you can do the rest of the re-assembly process yourself in the reverse order as listed above. I followed the service manual for this. If you are going to do this, let me know if you have questions. The manual was a little vague at a few points, but not too hard to follow. -- Brian
Surprises: -SOG stripped the crap out of the transmission drain plug when they swapped the fluid last month. It was also massively overtorqued, so it took me 20min to remove the bolt. It was impossible to remove without using Visegrips around the outside edge on the bolt, which IMO should always be the last resort. new bolt = $9 -clutch release pin: You need to remove a cap on the side with a 10mm allen wrench, screw in a 6mm bolt, and and pry the pin out. The service manual was a little vague here, but it was eventually figured out -reinstalling the tranny: you need 3 people for this if you don't have a proper transmission jack, 2 people under the car. The first step is to put the tranny on the 2 studs to get it started. Once this is in place, jack the back of the tranny up, with one person pushing it from the back. one shaking it from the middle, and one on top pushing the engine towards the back of the car. Also, if the splines don't align perfectly, rotate flywheel a little. The first attempt, I had put the release bearing on the pressure plate and not the fork, so it was not lining up perfectly, so we had to drop it down, and start over. That is about it. No specialized tools, aside from a ~1" long 6mm bolt for the clutch fork. With an early start, you can do it in one day, especially if you have help with the whole process. -- Brian
Wow Brian, quite the undertaking. Definite props for doing this yourself! I am hoping my clutch lasts long enough that I can swap it out when I swap out the short block.
I did my tranny all by myself 4 times. Lying under the car bench pressing that tranny is not a fun or pleasant experience. I couldn't imagine the heavier 6 speed being done like that....I guess I could do it if I had to but heh I won't.
Nice job! Man I should have called you Brian. Mine is at SOG now for other reasons but the clutch will be swapped out. Mine started slipping in 5th a few months ago. I'm right at 36k miles now.
This could be done yourself *IF* you have a tranny jack, without one it requires 3 people to do the job. It isnt all that complicated in reality, just nuts and bolts. It took some patience, a lot of coffee and some thinking but it was realtively smooth. The biggest bit we ran into was putting the tranny back onto the studs w/o first reassembling the clutch fork (lever). You want this in there first to prevent the tranny from any additional sort of movement while you're attempting to push it back together. Oh, and fawk is the tranny heavy
Yeah. Also when you drop that tranny you can visually see the little support the engine has as it just wiggles everywhere. When I was putting the tranny back on my car I had to lie on my back and bench press it while take my foot and pushing up on the engine. Coulda used a jack to jack up the engine a little but then the jack would be in my way.
Heh the 6 speed is almost 100 lbs heavier. I know it's not easy to bench press that thing in with it's uneven balance.....I've done it.