First Time Solo Clutch Change - Lessons Learned

[Sean240Z]

I just completed a solo clutch change for the first time and thought I'd document some of my lessons learned / tricks I picked up from my experience and various threads on this site:

Transmission Jack - 450 Lb. Capacity

- transmission jack really made the job easier

- I had to bend the strap mounting plates on the left side (far side in above pic) to clear my headers

- in my case, dropping the exhaust was a necessity to give me the required clearance to remove the transmission

- I pulled the fuel filter from its mount so that the fuel rubber fuel hose was not under stress

- I disconnected the upper radiator hose and removed the fan to allow the engine to rotate backwards

- disconnected the throttle rods also

- once I titled the engine and transmission down to remove the transmission, I put a small section of 2x4 between the head/valve cover and the firewall to limit the rotation

- I'm glad I did as I did the clutch change over a week or so, as I had to wait for the new clutch collar

- a few days later I went back to the garage and my floor jack that was supporting the engine had lowered and the engine was now resting on the 2x4

- my 240Z has five-speed from 280ZX installed

- when I removed clutch, I realized the pressure plate installed was a 240Z (240Z pressure plate on left, new 280ZX pressure plate on the right)

- new clutch pressure plate was much thinner, therefore required taller clutch collar

- ordered taller clutch collar from MSA

Motorsport! Clutch Collar, 75-83 Z/ZX Coupe Non Turbo, 84-86 ZX Turbo - The Z Store! Nissan-Datsun 240Z-260Z-280Z-280ZX-300ZX(Z31/Z32)-350Z-370Z Parts

- after reinstalling the transmission, I had trouble installing the clutch slave cylinder

- as I had changed the clutch collar with a taller unit, the clutch fork end now appeared to be slightly closer to the clutch slave cylinder

- what I should have done was to open the clutch slave cylinder bleed valve, to relieve some fluid/pressure to allow the clutch slave shaft to push further into the slave cylinder to allow for easier install

- what I did was force/lever the clutch slave cylinder into place

- after a number of simulated shifts in my garage (I wasn't making vroom vroom sounds, honest ), the clutch slave cylinder failed internally (i.e. metallic pop, clang, spring noise) and the clutch pedal went soft

- the clutch slave cylinder was probably ten years old but the timing of the failure leads me to believe that forcing the clutch slave cylinder into place wasn't a good idea

- I ordered a new Beck-Arnley clutch slave cylinder and installed

- I swapped out the Shift Lever End Bushing and the Shifter Pin Bushing

- wow, what an improvement in shifter feel (a lot of "slop" removed)

Motorsport! Shift Lever End Bushing, 82-83 280ZX Non Turbo - The Z Store! Nissan-Datsun 240Z-260Z-280Z-280ZX-300ZX(Z31/Z32)-350Z-370Z Parts

Motorsport! Shifter Pin Bushing, 82-83 280ZX Non Turbo - The Z Store! Nissan-Datsun 240Z-260Z-280Z-280ZX-300ZX(Z31/Z32)-350Z-370Z Parts

- I used long bolts with bolt head removed and slot cut into shaft

- screwed them finger tight into the top bolt holes in the head to line up transmission for install

- I first tried to install transmission with it in gear and it wouldn't go

- once I put transmission into neutral, install was easy and it slid right in

Anyway, I hope the above info helps.

Cheers,

Edited February 23, 2013 by Sean240Z

[Darrel]

I always recommend the headless bolts when lining up the tranny. Whether finding that tip on the forums or something you figured out on your own, good job.

[Sean240Z]

Thanks. I searched the forum for suggestions before I started the work and the headless bolts idea, was one I found.

Cheers,

[240260280z]

head bolts will do the trick too

[Reverend]

Good thread! I have few questions: i have 77 280z tranny and i have both small and big collars, when i bought the clutch i did not think any further and bought it for 240z, so should i use bigger collar? And does 240z slave cylinder work well with this setup?

Edited February 25, 2013 by Reverend

[Sean240Z]

Koalia - If the pressure plate you received in your clutch kit is truly a 240Z pressure plate (i.e. the thicker / taller one on the left in the image above), you would use the shorter / smaller collar.

Wrt slave cylinders, mine is the non-adjustable slave cylinder and fork from a later 280ZX. I understand the the 240Z slave cylinder was adjustable and had a slightly different fork. Can someone confirm?

[Reverend]

I have both 4speed fork and 5 speed fork, but does 240z WC work as "default" with 5 spd tranny?