Pics: How a baleno clutch got changed

gigy · 6th July 2007, 20:06

story in brife:
During the last Shirdi trip noticed she was struggling to climd the ghats towards the end. now she cant climb the slope near my house in peak traffic.
Since i had decided to replace entire clutch setup due engine high reving and clutch comparatively hard in comparision to my friend's baleno i though will share the procedure with fellow baleno owners. so i went off with my camera and was shooting down the sequence of events. As usual mid way the camera battery gave way and had to rely on phone camera. i hope this thread will be useful.
Went to Prakash motors at Milan subway and bought a ceekay clutch set Rs1850 and flywheel Rs750. didnt buy clutch release bearing and cable since both are a year old.last week i removed and fed lot of lubricant to the cable and it got real smooth when operated outside.clutch is a year old but has failed prematurely (20000kms).
That night going through the service manual i realized the clutch plate type specified in book was one containg 4 springs for 1.6 engine and the diagram showed the fingers on clutch housing were shorter. So morning rushed back to Prakash motors and got it replace to a valeo one which came cheaper Rs1650. Rahul was kind enough to replace although eh said the ceekay one is also fine. i wanted to follow the book
took all the spares and went to a known mechanic who has good workshop setup and started....

gigy · 6th July 2007, 20:24

the pictures

gigy · 6th July 2007, 20:30

difference between ceekay and valeo clutch. both may be interchangeable but i went for valeo

gigy · 6th July 2007, 21:11

having bit of trouble with imageshak.... moderators please delete repeat pictures.

this is the ceekay clutch plate with 6 springs

picture of new flywheel

gigy · 6th July 2007, 22:17

wheel removed

gear box out . found dirty black.

old clutch

after flywheel was removed found oil leak from rear oil seal, why it leaked? did change of oil from semi synthetic to synthetic caused this?
did this cause premature wear.

the old seal

had to rush for new seal, manged to buy from a dealer mgp item Rs130.

new flywheel in place

new clutch in place

gear box cleaned before installation

finally after closeup the drive was as good as ever thanks to propoer installation ans clutch setting by me mechanic.
so for baleno owners you can change the rear seal along with clutch change to prevent damages due oil leak or due to change of oil.

black12rr · 6th July 2007, 22:27

wonderful a picture is worth a 1000 or 10k words .Thanks for putting the pics , other should follow the same when reporting a error.

nitrous · 6th July 2007, 22:28

Good picture tutorial,man.
Btw,Why did u need to change the flywheel??

shrivz · 6th July 2007, 22:46

Great info there gigy..

I too need a clutch change soon.. this pictorial has really helped..

Just need a few clarifications..
Is the Valeo clutch you have the same as the "Valeo Performance Clutch"??

Why did you need to change the flywheel, as nitrous has already posted..

I believe there's a graphite ring which is an integral part of the clutch assembly, was that changed too?

thanks in advance..

cheers!
Shrivz...

gigy · 6th July 2007, 23:33

With earlier clutch setup had a sort of rubbing vibration when in 3 to 5k band which was felt on gear stick. This was there before and after clutch replacement last year. I had a feeling that since one side of clutch plate is very smooth (because its new) and other side the fly wheel has crossed 45k life could cause dynamic unbalance sort of thing. Due to this reason and when it cost only Rs750, i decided to get the flywheel also changed. now both side of plate is new and ultra smooth.
could have done disk cutting on the flywheel and got a performance mod called lightened flywheel but decided aganist it. since there is a basic problem of kr..kr...kr at high rev still not diagnosed. after replacement of full setup the smoothness is worth it.
i will recommend buying the engine rear end seal as its cheap(Rs130) and for older cars there could be leak.
if you have to replace this seal seperately it calls for removal of entire clutch and gear box. if its replacement is not required it can be returned.
shrivz,
are you refering to the clutch plate which has those graphite kind of black surface on both side? its part of the clutch package along with clutch cover.
this is not the valeo performance one, as the car is mostly city driven and bumper to bumper i prefer a soft clutch.

gigy · 7th July 2007, 10:21

forgot to mention labour charges Rs650.
here is the manual reference. which tells about number of springs in clutch plate-

http://i191.photobucket.com/albums/z...yk/clutch2.jpg

http://i191.photobucket.com/albums/z...yk/clutch1.jpg

mclaren1885 · 7th July 2007, 12:05

Gigy, I was just checking through a few spare parts lying at home. And yes the baleno clutches are indeed with 4 springs.

2fast4u · 7th July 2007, 12:49

nice info there gigy
hope u have used grease to lubricate the cable and Not oil.

gigy · 8th July 2007, 17:30

tried inserting grease into the clutch cable but it didn't go inside due to very less gap. cant remove the cable out of housing since one end is crimped . didnt want to cut it off and recrimp as i don't think it will be as strong as factor one. so filled the housing with liquid lubricant and in both ends pushed in grease. dont know if it will work but so far its very soft.

swathyd · 8th July 2007, 23:14

Good post gigy. Did you feel any jerking/vibrations (which we feel on clutch pedal) while shifting before this change of clutch ?

shrivz · 9th July 2007, 00:03

I'm referring to a graphite ring which sits over the clutch's fingers on one side (i think the outer side) when the clutch is engaged.. please correct me if i'm wrong here.. not sure about this technical detail...

6th July 2007, 20:06	#1
gigy Senior - BHPian Join Date: Jul 2006 Location: mumbai Posts: 1,321 Thanked: 47 Times	Pics: How a baleno clutch got changed story in brife: During the last Shirdi trip noticed she was struggling to climd the ghats towards the end. now she cant climb the slope near my house in peak traffic. Since i had decided to replace entire clutch setup due engine high reving and clutch comparatively hard in comparision to my friend's baleno i though will share the procedure with fellow baleno owners. so i went off with my camera and was shooting down the sequence of events. As usual mid way the camera battery gave way and had to rely on phone camera. i hope this thread will be useful. Went to Prakash motors at Milan subway and bought a ceekay clutch set Rs1850 and flywheel Rs750. didnt buy clutch release bearing and cable since both are a year old.last week i removed and fed lot of lubricant to the cable and it got real smooth when operated outside.clutch is a year old but has failed prematurely (20000kms). That night going through the service manual i realized the clutch plate type specified in book was one containg 4 springs for 1.6 engine and the diagram showed the fingers on clutch housing were shorter. So morning rushed back to Prakash motors and got it replace to a valeo one which came cheaper Rs1650. Rahul was kind enough to replace although eh said the ceekay one is also fine. i wanted to follow the book took all the spares and went to a known mechanic who has good workshop setup and started....
	() Thanks

6th July 2007, 20:24	#2
gigy Senior - BHPian Join Date: Jul 2006 Location: mumbai Posts: 1,321 Thanked: 47 Times	the pictures
	() Thanks

6th July 2007, 20:30	#3
gigy Senior - BHPian Join Date: Jul 2006 Location: mumbai Posts: 1,321 Thanked: 47 Times	difference between ceekay and valeo clutch. both may be interchangeable but i went for valeo Last edited by gigy : 6th July 2007 at 20:48.
	() Thanks

6th July 2007, 21:11	#4
gigy Senior - BHPian Join Date: Jul 2006 Location: mumbai Posts: 1,321 Thanked: 47 Times	having bit of trouble with imageshak.... moderators please delete repeat pictures. this is the ceekay clutch plate with 6 springs picture of new flywheel
	() Thanks

6th July 2007, 22:17	#5
gigy Senior - BHPian Join Date: Jul 2006 Location: mumbai Posts: 1,321 Thanked: 47 Times	wheel removed gear box out . found dirty black. old clutch after flywheel was removed found oil leak from rear oil seal, why it leaked? did change of oil from semi synthetic to synthetic caused this? did this cause premature wear. the old seal had to rush for new seal, manged to buy from a dealer mgp item Rs130. new flywheel in place new clutch in place gear box cleaned before installation finally after closeup the drive was as good as ever thanks to propoer installation ans clutch setting by me mechanic. so for baleno owners you can change the rear seal along with clutch change to prevent damages due oil leak or due to change of oil.
	() Thanks

6th July 2007, 22:27	#6
black12rr Senior - BHPian Join Date: Dec 2005 Location: Ridin earth now Posts: 1,278 Thanked: 339 Times	wonderful a picture is worth a 1000 or 10k words .Thanks for putting the pics , other should follow the same when reporting a error.
	() Thanks

6th July 2007, 22:28	#7
nitrous Senior - BHPian Join Date: May 2004 Location: UAE/Lon/Madras Posts: 6,965 Thanked: 325 Times View My Garage	Good picture tutorial,man. Btw,Why did u need to change the flywheel??
	() Thanks

6th July 2007, 22:46	#8
shrivz BHPian Join Date: Jan 2006 Location: Pune, MH12 Posts: 604 Thanked: 96 Times View My Garage	Great info there gigy.. I too need a clutch change soon.. this pictorial has really helped.. Just need a few clarifications.. Is the Valeo clutch you have the same as the "Valeo Performance Clutch"?? Why did you need to change the flywheel, as nitrous has already posted.. I believe there's a graphite ring which is an integral part of the clutch assembly, was that changed too? thanks in advance.. cheers! Shrivz...
	() Thanks

6th July 2007, 23:33	#9
gigy Senior - BHPian Join Date: Jul 2006 Location: mumbai Posts: 1,321 Thanked: 47 Times	With earlier clutch setup had a sort of rubbing vibration when in 3 to 5k band which was felt on gear stick. This was there before and after clutch replacement last year. I had a feeling that since one side of clutch plate is very smooth (because its new) and other side the fly wheel has crossed 45k life could cause dynamic unbalance sort of thing. Due to this reason and when it cost only Rs750, i decided to get the flywheel also changed. now both side of plate is new and ultra smooth. could have done disk cutting on the flywheel and got a performance mod called lightened flywheel but decided aganist it. since there is a basic problem of kr..kr...kr at high rev still not diagnosed. after replacement of full setup the smoothness is worth it. i will recommend buying the engine rear end seal as its cheap(Rs130) and for older cars there could be leak. if you have to replace this seal seperately it calls for removal of entire clutch and gear box. if its replacement is not required it can be returned. shrivz, are you refering to the clutch plate which has those graphite kind of black surface on both side? its part of the clutch package along with clutch cover. this is not the valeo performance one, as the car is mostly city driven and bumper to bumper i prefer a soft clutch.
	() Thanks

7th July 2007, 10:21	#10
gigy Senior - BHPian Join Date: Jul 2006 Location: mumbai Posts: 1,321 Thanked: 47 Times	forgot to mention labour charges Rs650. here is the manual reference. which tells about number of springs in clutch plate- http://i191.photobucket.com/albums/z...yk/clutch2.jpg http://i191.photobucket.com/albums/z...yk/clutch1.jpg
	() Thanks

7th July 2007, 12:05	#11
mclaren1885 BANNED Join Date: Jul 2005 Location: Bangalore (the city of modded cars) !! Posts: 4,820 Thanked: 45 Times View My Garage Infractions: 0/1 (10)	Gigy, I was just checking through a few spare parts lying at home. And yes the baleno clutches are indeed with 4 springs.
	() Thanks

7th July 2007, 12:49	#12
2fast4u BHPian Join Date: Mar 2005 Location: pune / Bahrain Posts: 488 Thanked: 7 Times View My Garage	nice info there gigy hope u have used grease to lubricate the cable and Not oil.
	() Thanks

8th July 2007, 17:30	#13
gigy Senior - BHPian Join Date: Jul 2006 Location: mumbai Posts: 1,321 Thanked: 47 Times	tried inserting grease into the clutch cable but it didn't go inside due to very less gap. cant remove the cable out of housing since one end is crimped . didnt want to cut it off and recrimp as i don't think it will be as strong as factor one. so filled the housing with liquid lubricant and in both ends pushed in grease. dont know if it will work but so far its very soft.
	() Thanks

8th July 2007, 23:14	#14
swathyd BHPian Join Date: Mar 2007 Location: thiruvananthapuram Posts: 774 Thanked: 25 Times	Good post gigy. Did you feel any jerking/vibrations (which we feel on clutch pedal) while shifting before this change of clutch ?
	() Thanks

9th July 2007, 00:03	#15
shrivz BHPian Join Date: Jan 2006 Location: Pune, MH12 Posts: 604 Thanked: 96 Times View My Garage	I'm referring to a graphite ring which sits over the clutch's fingers on one side (i think the outer side) when the clutch is engaged.. please correct me if i'm wrong here.. not sure about this technical detail...
	() Thanks