Pending clutch job. How likely is it I will need a new flywheel?

[nesticle]

Hi all. My clutch is finally starting to slip when bogging the transmission (which makes it pretty useless when trying to pull a quick turn in an intersection). as well as slipping a bit on steep hills. Car is a 96 ti with about 80k miles on it. There are no chattering, grinding or whining noises involved with this, so I'm wondering how likely it is that I will need to replace the flywheel. I've read that they are quite expensive so replacing it is something I would rather not do.

Thanks in advance.

[cooljess76]

Not likely at all. Just buy a clutch kit - pressure plate, clutch disc, clutch release bearing(throwout bearing) and pilot bearing. The kit should come with a clutch alignment tool and can usually be purchased for around 200 bucks.

[96cali]

This project has been looming on my horizon for a while (I have the whine but no slip). How difficult is this job?

[J!m]

Tough to answer-

difficulty has everything to do with your personal skill and comfort level more so than anything else.

This is not changing a headlight bulb, but is not an engine rebuild either.

I suggest you pick up the Haynes manual which is good enough to explain the clutch job step by step. If you think you can handle it, go for it! Note you will need some female TORX sockets for removing the tranny...

[nesticle]

Just thought I'd update. I didn't trust myself to do the work (I'm fairly mechanically inept), so I had my mechanic do it. I took a look at the flywheel when he had it all apart and it looked glazed and burnt. I don't know if anyone else has doen this, but he just sanded that stuff off the surface and put the new clutch in. He must have done something right because the clutch doesnt pulse (like it would if it were unbalanced), nor does it chatter or anything. The thing feels great now and boy does it EVER grab.

So yeah, sanding the flywheel, replacing the clutch, the slave cylinder (i figured i'd get it done while its accessible), transmission seal, downpipe gasket and labour came out to $1200 + a case of beer. I'm just glad I didn't have to replace the friggin flywheel. That would have easily doubled the bill.

[J!m]

Glad it worked out.

Yes, I have sanded flywhel faces before. Aslong as it is still flat, and not dished or grooved, this works fine to remove the glaze. I typically use Roloc scotchbrite pads to do it myself, but a D-A ith 180 mon it works well too.

With sanding, it can be a bit grabby at first, but it will smooth out over time.

[96cali]

Originally Posted by J!m

Note you will need some female TORX sockets for removing the tranny...

As nicely detailed in your swap manual.

Loving the manual.... not now honey, Imma lookin' at car porn tonight.

[J!m]

Glad you got it and like it.

If you need wirig diagrams for the donor car, let me know. Just cover shipping the CD since you bought the manual from me. ti wiring diagrams are listed here somewhere- there is a link from my for sale post.

If you need others (going pretty far back) please see my post in the for sale section. I have a LOT of them now...

[96cali]

Thanks for the offer Jim.

[mohaughn]

Originally Posted by nesticle

Just thought I'd update. I didn't trust myself to do the work (I'm fairly mechanically inept), so I had my mechanic do it. I took a look at the flywheel when he had it all apart and it looked glazed and burnt. I don't know if anyone else has doen this, but he just sanded that stuff off the surface and put the new clutch in. He must have done something right because the clutch doesnt pulse (like it would if it were unbalanced), nor does it chatter or anything. The thing feels great now and boy does it EVER grab.

So yeah, sanding the flywheel, replacing the clutch, the slave cylinder (i figured i'd get it done while its accessible), transmission seal, downpipe gasket and labour came out to $1200 + a case of beer. I'm just glad I didn't have to replace the friggin flywheel. That would have easily doubled the bill.

The biggest thing is if the dual mass part of the flywheel is damaged, the flywheel has to be replaced. You can find machine shops that can resurface a dual mass flywheel as well. The clutch went out on my E39 and I ended up having to get the flywheel replaced as well because there was a lot of play in the dual mass part, that sucked.

If you catch that the clutch is slipping early enough, and get it fixed right away it is unlikely that you will damage the flywheel. In my case there was something wrong with the flywheel shaft and the way that the throwout bearing was sitting on that shaft. I almost think the guy that owned the car before me didn't know how to drive stick shift and damaged the entire clutch assembly, which then slowly destroyed the flywheel.