Narrywoolan*

Clutch Repairs: 2008 - 2009. Revised in 2012.

First the story:


On the way to the Australian Lancia Register Castlemaine Rally on Thursday 18th October 2007, 200 km from home just outside sunny Rosedale, the clutch broke. I’d stopped for a loo break and when I tried to start the car nothing happened. Thinking the starter motor might have jammed I pushed the car back and forward, tried again. It started but there was a horrible rattle and no clutch, bugger! Called the RACV, fours later the tow truck arrived, a further four hours and we were back home.


Crawling underneath removing the gearbox inspection plate and out fell a piece of broken spring! Called this fellow by the name of Andrew Cox, he had some spare clutches so we arranged to meet the next day. In the meantime I started to try and get the gearbox out. Around 11pm I called it quits, having already been up since 6am and driven 450 km. Up early next morning to meet Andrew 350 km away in Berwick, collected a box of bits and drove back home. Again around midnight I gave up, I couldn’t get the gearbox out. Next morning drove the Land Rover the 500 km to Castlemaine.


Two weeks later I moved from W Tree to Venus Bay, the Lancia travelled on a trailer. I took me until May 2008 to get the new workshop sorted and to start repairs. In the meantime I’d read lots, got copies of the instruction manuals and received much valuable advise from Andrew and Peter Renou.


Below is a pictorial story of the repairs...

Early 1st series clutch.
Early 1st series clutch.
October 2007.
Note the modified transmission tunnel.
October 2007.
Note the modified transmission tunnel.
It does allow easy access to the gearbox top. Also note modified gearbox
 mounting set-up!
It does allow easy access to the gearbox top. Also note modified gearbox
mounting set-up!
Aprilia Clutch-004.jpg
Aprilia Clutch-004.jpg
Just no way to get the gearbox out.
Just no way to get the gearbox out.
Midnight. As far as I could get.
Midnight. As far as I could get.
May 2008. Let’s get going.
Step one, remove engine & gearbox.
May 2008. Let’s get going.
Step one, remove engine & gearbox.
Radiator, engine & gearbox in one piece.
Radiator, engine & gearbox in one piece.
The offending clutch with temporary replacement spring.
The offending clutch with temporary replacement spring.
Springs & a bit of rust - not the real problem!
Springs & a bit of rust - not the real problem!
Flywheel, a bit grotty but no distortion.
Flywheel, a bit grotty but no distortion.
Broken double hairpin clutch spring. Everyone said. “Never seen that happen before!”
Broken double hairpin clutch spring. Everyone said. “Never seen that happen before!”
Original clutch plate
Original clutch plate
Damage to centre rivets when the thing seized.
Damage to centre rivets when the thing seized.
Evidence of heat on the pressure plate.
Evidence of heat on the pressure plate.
Close up, notice all the metal fillings.
Close up, notice all the metal fillings.
The root cause of the failure, the clutch withdrawal bearing had seized.
The root cause of the failure, the clutch withdrawal bearing had seized.
Withdrawal bearing, p/no. 38-164.
Replaced with NSK 35TNK20
(See section below)
Withdrawal bearing, p/no. 38-164.
Replaced with NSK 35TNK20
(See section below)
Replacement clutch plate from Andrew Cox. Relined by BGT in Dandenong.
Replacement clutch plate from Andrew Cox. Relined by BGT in Dandenong.
Getting the alignment set up, with my little home made tool.
Getting the alignment set up, with my little home made tool.
All back together with six replacement springs.
All back together with six replacement springs.
View through bottom inspection plate hole.
View through bottom inspection plate hole.
Ready to go back in the car.
Ready to go back in the car.
Simply drop it back in, piece of cake!
Simply drop it back in, piece of cake!
2012. Out comes the engine - again.
2012. Out comes the engine - again.
For some strange reason it was quite nice to have the engine sitting on the bench again, it’s such a lovely thing.
For some strange reason it was quite nice to have the engine sitting on the bench again, it’s such a lovely thing.
The incorrect size NSK bearing.
Aprilia lesson one: Always fit an original part.
The incorrect size NSK bearing.
Aprilia lesson one: Always fit an original part.
Started to overheat on long journeys making nasty noises.
Started to overheat on long journeys making nasty noises.
New NOS bearing from Cavalitto €160
New NOS bearing from Cavalitto €160
Note the fitting.
Note the fitting.
In it goes.
In it goes.
46mm socket does up the retaining nut.
46mm socket does up the retaining nut.
Fitted back on the flywheel.
Fitted back on the flywheel.
To keep Ben Courage happy I took the opportunity to fit the correct spring retaining bolts.
To keep Ben Courage happy I took the opportunity to fit the correct spring retaining bolts.
Not all is what it seems.
Variations on early clutch collars (A)
Later clutch is bigger at B.
Not all is what it seems.
Variations on early clutch collars (A)
Later clutch is bigger at B.
Variations on clutch bearings. The NSK on the right is wrong!
Variations on clutch bearings. The NSK on the right is wrong!
Why does the one on the left have the stamp and which one is correct?
Why does the one on the left have the stamp and which one is correct?
November 2012
An original RIV bearing. Found two on the interweb!
November 2012
An original RIV bearing. Found two on the interweb!
Note part number and dimensions
Note part number and dimensions
This bearing is the same type as the one that seized back in 2007.
This bearing is the same type as the one that seized back in 2007.
Still with original packing grease. It is essential to have the larger inside diameter at the end that rotates.
Still with original packing grease. It is essential to have the larger inside diameter at the end that rotates.
You need to return this with the bearing for any claim. It might be just out of the warranty period now
You need to return this with the bearing for any claim. It might be just out of the warranty period now
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In 2012 I replaced the bearing I’d fitted back in 2009!