Clutch/Flywheel Replacement...Gear box too?

[jwinlaporte]

Well I haven't posted in a while, but that's because my ti has been running great--until the clutch went out.

I have it torn down, here's the situation: With questions. . .1996 ti with 243,000 miles.

Transmission has original VIN number, and it's been out before. This is obvious because several star bolts were missing or stripped on bell housing.
Friction plate was key holed and about 1/2 less in diameter than it should be as outside edge is chewed up. Flywheel is junk.
Is the dual mass flywheel supposed to have play and spin on itself? The bolt heads on the flywheel were worn down.

Question 1: Do you think I should not reuse gearbox with it having 240K miles? Follow up? You got one with fewer miles?
Question 2: What is the lowest priced, decent quality direct fit flywheel clutch combo out there? This will be my first manual transmission job. . . and I want to make sure whatever goes back in will bolt up and reassemble correctly the first time. Any input/advice about reassembly. Maybe CoolJess wants to come to Indiana and put trans back in without a jack--I remember those pictures a while back...

[jwinlaporte]

There was no pilot bearing present when I separated the engine/transmission.
I don't know if it was not installed or completely disintegrated.

[zoner]

Don't forget to replace the clutch fork pivot pin as well!

There was a guy on ebay that was selling Luk dual-mass flywheels and Luk clutches for under $700 for both. That's not a bad deal for new parts, IMO. If you're just looking for stock replacement parts, I'd start there.

[jwinlaporte]

Lots of sellers on ebay...
Prices range 200 to 3000!
Does his stock kit include the little things too?

Right, I saw somewhere here about that pin being very important.
Basically, to save money and maybe have a little more fun with it...
I'm thinking about switching to solid flywheel and the appropriate clutch assembly.
But I'm worried that there's too many miles on the gearbox--over 240 K miles.

[jwinlaporte]

Will it fit???
According to realoem.com the ti has--S5D 250G - TBDH
Will a Getrag 250G - TAJT (FROM A 1999 323) fit into a ti with no modifications?

What is the difference between the initials at the end? The case appears to be identical?

So far the only difference I see is in the size of the clutch assembly. The 6 cyl has a bigger diameter clutch etc.
Does anyone know where I can find gear ratios? The last 7 digits of the donor transmission are AE15673...it was a 97 323i.

If the gear ratios are too different, will I be able to drive it?

I found this website: http://www.bokchoys.com/differential/GearRatios.htm
which says the gear ratios are identical.

So, I'm going to install the Valeo Solid Flywheel conversion kit for the TI, into a donor transmission from a 323--just as soon as it all gets here. . .

Should be a done deal for under $1000!


Back on the road!

[jwinlaporte]

I got an error message trying to answer a private message, so here's the question and response pasted below . . .

Hey,

Saw that you installed the valeo solid flywheel conversion about a year ago. Any issues with that kit? Daily driveability okay? Do you remember if the flywheel is lighter than the stock dual mass?

Dave

I did have trouble with pilot bearing...the one supplied was damaged and incorrect. Eventually got one at NAPA. Delayed installation by a couple days.

Yes, about one year on the new clutch. It is still smooth as butter. Absolutely no performance or daily driving complaints whatsoever.

Now, about the weight...the flywheel is still pretty hefty...after all, it's a solid single mass...this is why it feels so close to stock. I do think you'll end up saving 3-5 pounds under the stock set up.

Price...it's way cheaper to switch to Valeo kit than to buy a new dual mass flywheel and clutch assembly.

If you're trying to keep a daily driver on the road, then absolutely get that Valeo conversion kit. Cheaper than stock and performance is, I think, a wee bit better!

[spidertri]

Hah, sweet. I saw that kit last night and found your thread. Glad to hear it has served you well. I'd like to go to a single mass flywheel but most of the options hit the wallet pretty hard. This looked like a good alternative.

[jwinlaporte]

No doubt. Good luck!

[pvansickler]

JWINLAPORTE... Do you have the Kit Number for the Clutch Conversion kit you installed and was it for the M44 motor? I have a 1998 and want to install a robust clutch system for when I supercharge the 1.9 motor. Thanks you for the info.

[spidertri]

Valeo 52161203 is the single mass conversion for the M44. It is stock replacement, not designed for more power.

[pvansickler]

Any suggestions for a higher performance clutch set-up?

[pvansickler]

Any thoughts on installation of an lightweight single mass flywheel? Looking to accelerate faster for autocross racing and looking for areas for improvement while upgrading things along the way.

[jAladdin]

jwinlaporte, whats up man,

Im really looking into the Valeo kit, because of its price. Was there any problems with the installation? Since its a single mass, does it need any
mods, or does it just fit right into place? I have no exprience whatsoever, so please bare with me. I'm having a friend help me out with the clutch/fw
replacement.

Any cons with running this kit?

Please respond asap, as for i am ready to order this kit within a few days, haha. Thank you a lot in advance :)

[pvansickler]

I went with the UCC Lightweight Flywheel for '92-'99 E36 3-series, M3, Z3 & E34 525i - 8.5lbs - M5 sprung-hub clutch $974

Went this route as we will be adding a S/C to the motor so didn't want to go back and replace Clutch/flywheel for the more Hp...

Nice thing about the Lightweight Flywheel is that it can be rebuilt as well...

http://store.uucmotorwerks.com/lightweight-flywheel-for--92-99-e36-3-series-m3--z3--e34-525i---85lbs---m5-sprung-hub-clutch-p194.aspx

[jAladdin]

pvansickler,
Thanks for your input, buddy. That setup sounds great, but I'm just a Stanced Daily looking for a stock kit, LOL. Mainly because of the price. I think the Valeo kit with be fun enough. I'm just tired of a slipping clutch... Although it still functions good enough to be daily'd. At 153k miles, and with that slipping, its about time for a replacement.