Kamen Posted September 2, 2016 Share Posted September 2, 2016 My question today is about the clutch in my 2002 WRX manual (I know, it's not a Legacy but they are the same) that I'm replacing (for the 4th time). I ordered an Exedy/Daikin KSB03 (OEM) kit from Amazon and it seems not right. The gaps between the pressure plate fingers and those support tabs (what's their proper name?) varies a lot. I don't think they're supposed to ever touch but one of them is already touching and I think that's not right. Here are some pictures. This is a general view: http://i.imgur.com/B5XDfdy.jpg This shows four of them and you can see how they vary in gaps: some are right in the middle, others are close to the fingers, and one is touching. http://i.imgur.com/28GNzCN.jpg This close-up shows two adjacent tabs to illustrate the difference: http://i.imgur.com/xvB1LAS.jpg The left one (red) seems like it's propping the finger up and wouldn't even let it go down when pulled. I can get much better pictures, if needed. It seems to me like that could be a problem. Is this a sign of a defective clutch that I should return, or is this something I could straighten out myself (I paid a lot less than the normal price as it had "cosmetic imperfections")? Kamen Link to comment Share on other sites More sharing options...
Max Capacity Posted September 3, 2016 Share Posted September 3, 2016 Sorry I can't view the pictures here at work. Did you call Exedy ? They have great customer service, or did back in the day. For the record, I have had great performance out of Spec Clutches. You might want to try and PM "cryo" he may be able to help answer your question, you can tell him I sent you. Your XT may like what he can do for that car. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
Kamen Posted September 3, 2016 Author Share Posted September 3, 2016 Thanks, I have PM'd him. I got the clutch yesterday afternoon, so I wasn't able to call Exedy, but I will as soon as the holidays are over. I used to have a Spec carbon-Kevlar clutch, but it was the one that lasted me the least. It was because I didn't bed it in properly, but it was also very expensive - 3 times what I paid for this one ($150). Stock is fine for me, at this time. Kamen Link to comment Share on other sites More sharing options...
Kamen Posted September 3, 2016 Author Share Posted September 3, 2016 Update: I stopped by the service department of my local dealership and showed them the clutch. They said there is no problem and that those tabs will not be interfering with the fingers. The latter, plus their explanation of how the throwout bearing is pulling on the pressure plate, were wrong (he was showing in the wrong direction). He was just the "service advisor", but it gives me a bit of confidence that they don't run into this kind of problem, so it's probably nothing to worry about. I will, however, contact Exedy on Tuesday to make sure. I also tried to bend the tabs to see how that would work out and it was rather easy, so I straightened them all out and now there is good clearance. I can't imagine this contraption (the "tabs") has any continuous function, maybe some sort of fail-safe? After close inspection, I noticed some scratches on the pressure plate surface. Here are some pictures: General view: http://i.imgur.com/JPbQy1b.jpg http://i.imgur.com/AIcPAS4.jpg http://i.imgur.com/aMsIUXe.jpg And here are some close-ups of the scratches: http://i.imgur.com/a76YIWJ.jpg http://i.imgur.com/YVxV2Fy.jpg http://i.imgur.com/8Pmon9g.jpg They seem rather negligible, but I thought I'd post the images. Kamen Link to comment Share on other sites More sharing options...
Max Capacity Posted September 4, 2016 Share Posted September 4, 2016 The last picture is the only one I'd be concerned with. A light sanding may take off the sharp edges. Here's my Spec 2 PP before I installed it. http://i185.photobucket.com/albums/x40/92Si/DSCN4786.jpg After looking at the old Spec 2+ PP after 85,000 miles you won't even be using the area in your third picture. http://i185.photobucket.com/albums/x40/92Si/DSCN4722_zps0a5c3e60.jpg 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
Kamen Posted September 5, 2016 Author Share Posted September 5, 2016 Thank you, very much! I'll confirm the coverage of the friction surface of the organic OEM clutch, but I feel it will be pretty much the same. As for the sanding - I had that thought, too. I also got a response from a local transmission builder and he said that the "tabs" (which seem non-existent on the Spec pressure plate) on the clutches he currently has at the shop are equally spaced between the fingers. I'm really curious about what Exedy would say (if they respond at all). By the way - 85K miles on a clutch? I've never had one last more than 25-30K. But my transmission lasted 170K. I guess, different driving styles. Kamen Link to comment Share on other sites More sharing options...
Max Capacity Posted September 5, 2016 Share Posted September 5, 2016 Yea 85K and it was still strong, I replaced because I put the new engine in. The Spec 2 only lasted 50K at my HP level, I had a 2+ out back in March 2015. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
Kamen Posted September 6, 2016 Author Share Posted September 6, 2016 I looked at it some more and on the OEM clutch the friction surface's width is the same on the clutch disk as on the pressure plate: http://i.imgur.com/QdaqSNg.jpg You can see it less clearly here, but when overlaid, you can barely see the pressure plate: http://i.imgur.com/Zgen9ST.jpg Also, the scratches are deep enough to catch a fingernail, but I think I can smooth them out. But, let's see what Exedy has to say, if anything. Kamen Link to comment Share on other sites More sharing options...
Kamen Posted September 6, 2016 Author Share Posted September 6, 2016 I just called Exedy and talked to one of their tech support people and they said that the uneven distribution of those tabs was normal; he said he was looking at a product photo and they were just like on the one I have: unevenly distributed, and some even touching. He said those have no other function than to help in the assembly process. I also asked him about the scratches (yes, they'd catch a fingernail, lightly) and he said that it shouldn't be a problem, as long as they are not deep dents. He suggested I smooth out the edges with some sandpaper, but he assured me it would be alright. At this point I have enough assurance that there is nothing wrong with the clutch kit, so I plan to get the install started next weekend. Thanks to all who helped! Kamen Link to comment Share on other sites More sharing options...
Max Capacity Posted September 6, 2016 Share Posted September 6, 2016 All right, good luck with the install. Make sure the fork doesn't fall off the pivot ball while you moving the tranny around trying to get it bolted up. check the fork before you put all the bolts in driveshaft, etc and start the car to find out you can shift, and then take everything back out and pull the tranny back and see the fork has fallen off the ball...yea, that was fun. 305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD). CHECK your oil, these cars use it. Engine Build - Click Here Link to comment Share on other sites More sharing options...
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