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nathan

Navara Clutch Replacement

Ultralube Wheel

Navara Clutch Replacement

Diagnosis:

At this time we had a few cars come in with slipping clutches or unable to select gears. Our first step is always to confirm the concern which involves taking the vehicle for a road test and monitoring what happens.

This vehicle was increasing revs while in gear but not increasing speed but the clutch pedal travel felt fine. Which is normally a sign of a slipping clutch. We proceeded to test the clutch fluid, which failed due to moisture content, and check the clutch pedal adjustment to make sure that it was not continuing to apply pressure to the clutch plate.

Disassembly:

Upon removal of the gearbox, we found a lot of clutch fibers released from the friction plate. The fibers built up all around the starter motor and in front of the release bearing. The retaining spring for the clutch fork had broken in addition to excess wear between the fork and pivot ball.

Once the clutch was removed we found the friction plate was down to assembly rivets. Both the pressure plate and flywheel had sever discoloration. This discoloration is caused by hot spots in the metal due to excess slipping.

Repair:

During reassembly we cleaned down the inside of the bell housing, rear of the engine block and the starter motor to remove all potential contaminants. We sent the flywheel out to be machined in order to give the new clutch the best chance for survival. The worn clutch fork, fork pivot and retainer were replaced in conjunction with a new Clutch Industries clutch kit containing; release bearing, spigot bearing, pressure plate and friction plate.

Once assembly was completed, the hyrdaulic controls for the clutch were flushed with fresh brake fluid and then the pedal was adjusted to ensure correct bite and release point of the system for longest life.

Finally, it was road tested for quality control.

The clutch kit we used was from Clutch Industries

Volkswagen Touareg

Why is there Volkswagen Touareg engine on the floor?!

One of our regular customers recently presented their Touareg with a few tricky concerns for us to solve.

The first issue to tackle was a rattle that happened during first start up in the morning and only lasted for a few seconds. Easy to miss but our diligent customer is very aware of his car. We managed to narrow this rattle down to the timing chain tensioner which was losing pressure over time while the engine was off.

Unlike most vehicles we work on, this Volkswagen decided it was a good idea to position the timing chains at the rear between the motor and transmission. This required the complete removal the very heavy motor and gearbox assembly out of the bottom of the car so that we had enough room to remove the transmission.

From there we had plenty of space to fit a new timing chain kit containing both of chains and tensioners.

We managed to successfully reassemble the whole system no dramas.

The next issue was with the throttle – not quite as responsive as it once was. We noted a large amount of sludge (exhaust gas and crank case gas combined) build up in the intake manifold and on the swirl flap plate. While this build up is fairly normal in diesels it is far less then ideal as it restricts air flow to the motor.

Cleaning the sludge off was fairly straight forward as we already had most of the intake system removed. Normally at this point we would suggest fitting a Catch Can to help prevent the build up in the future, however as there are no readily accessible kits for this vehicle we recommended that we carry out other preventative measures like on board cleaning of the intake every service.

Replacement of the leaking water pump and worn drive belt were very straight forward as was completing a minor service at the same time.

Notes:

The motor was repositioned from the bench onto the floor for safety. I did not want that bad boy coming down!

The drivers side intercooler is perfectly set up to catch a lot of oil so we shall be draining this component fairly often.

Do you have a niggling concern with your car? Looking for a mechanic in the midland area to problem solve that odd ticking sound? Give us a call at Ultra Lube Mechanical Workshop and see what we can do!