Clutch on its last legs

[FarmerPug]

I towed a trailer a few weeks back, to a friends house which was in a cull de sac at the top of the hill, this meant a bit of reversing with a trailer on behind which has buggered my clutch, which was slipping before.
Now the car rattles and makes all sorts of noises at idle, and whines with the engine rpm, i think the DMF is breaking up and the release bearing is shot.

A new DMF kit, i don't think i want a solid conversion, is £270 for a LUK kit. Are there any other things to change while in there? Probably crankshaft oil seal being a good one, would the subframe bushes need replacement?

I also have, and have had a vibration in the steering wheel at around the 70mph mark, its very subtle and didn't change with the wheels getting balanced it seems to be most noticeable when at speed on the motorway then let off on the accelerator there is noticeable vibration. Could this be the dmf as it breaks up, or bad drives? The suspension components round the front show no signs of play.

[jasper5]

You don't need to replace the subframe bushes...you don't need to take it off...maybe undo some of the bolts and pull it down a bit, but not out.
The driveshaft oil seals and maybe the lower engine mount could be replaced whilst the driveshaft is out.
The sleeve that the release bearing slides on could be replaced...sometimes they get damaged.

Personally I wouldn't be looking at the vibration until the clutch/flywheel job is completed.

[FarmerPug]

Ive just started the clutch tonight, so far got one driveshaft out, noticing though that the lower balljoints are very loose, no splits in their boots but feel very loose like the knackered joints in the droplinks, i can feel the track rod end balljoints and they are not really loose at all.
I think these lower balljoints are whats causing the vibration

[FarmerPug]

Here are some pics of the job so far, was talking to a chap who breaks 406es not far from here he said to drop the subframe as it only takes about 20 mins extra, fair enough it did. thankfully all 4 bolts came out without the nut breaking loose, although they were rather rusty, might be just as well removing the subframe to get a bit of engine oil/grease mix up into the cavities to stop any rust. It also made getting the rear engine mount looked at, its not completely shot but there is some play in the old one.


The engine is, and always has been a bit messy around the drivers side, I've never noticed any oil usage between the 10,000 mile change interval but don't like the look of this:

I put a new crankshaft seal into it about 2 years ago when doing the timing belt, and a new water pump. Oil is everywhere, also there are some visible coolant drops.

[steve_earwig]

Argh! So I guess you'll also be doing a cam belt on it too Any idea where the oil slick's coming from? I suspect that's too much to be left overs from the cam oil seal.

Will there be videos?

[flyin2wheeler]

one clutch not to use...borg and beck.
I put one in my 04 90 hdi in april and its slipping now so,its looking like I will be fitting another but I will get a valeo kit next time.
Pure pain in the ass having to fork out again 6 months down the line and I would have tought B and B would have been a quality clutch mfr

[FarmerPug]

Yes working on the video at the moment.

Ill take a look at the cam belt soon enough, im doubting if the oil leaks coming from the crankshaft seal seems to be originating higher than that, its always been a bit oily round here same on my mums xsara. The coolant is a bit more worrying, i think using instant gasket in addition to the gasket that came with the pump may not have been the best idea.

The cars back together and driving, slight blow in the exhaust i think something is not on right. But driving perfectly, no juddering and the lower balljoints seem to have solved the annoying vibration.
Here are some pictures:

Release bearing dust:

An engine minus the flywheel, i didnt bother changing this seal as it doesnt seem to be leaking


Got a nice grease and engine oil mix into the subframe bolt holes:


The old clutch and DMF:

I have fitted a LUK kit, interestingly a LUK flywheel was what had been fitted previously. The question is what was fitted originally to 406es when the left the factory? I always thought Valeo made the clutch kits, it would be good to know if this previous DMF was the original or if it had been changed at some time by the previous owner.



The new clutch in place:

[Welly]

What a job!

[jasper5]

LUK are the original clutch supplier.

Regarding Borg and Beck clutches...B & B don't make clutches any more you get what you get in the box...sometimes you get a Valeo clutch in the box....I've had a couple of Valeo ones.

Personally, i've never had a bad clutch from B & B.

[FarmerPug]

Jasper are the LUK bonus points of any use to you? This kit came with these coupons:

[jasper5]

Thanks for the offer, but I don't do clutches any more if I can help it...I did a Focus a couple of weeks ago for my wife's friend ...with help, but it was a one off.

[FarmerPug]

Here is the video:
wuA1looYGH8

[Welly]

That video is amazing! it must have taken a lot of thought to do the work in conjunction with getting the right camera work so very well done. Looks like you did the work at night too?

Nice work in marking the bolts once torqued

[FarmerPug]

Ahy it was mostly nightime work 2:00am on the Saturday morning when i was changing over the flywheel. its not my shed with the lift and its crying out for some overhead lights.

[steve_earwig]

Just watching the vid now - I've just watched the bit where you undo the engine mount, just after the bit "make sure the strap holding the engine up is secure" and, even though I know this job is done and disted for a fracction of a second I though the engine was going to fall out on the deck

Edit: I just watched that bit again - I think you did too!