Project Bugeye GDA WRX: Fixing the Clutch with Exedy

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Next, the clutch alignment tool is used to get everything lined up as the pressure plate is installed.

Here is Ian’s old clutch disc, soaked in all sorts of different fluid and totally worn out.

Howard decided to reseal Ian’s transmission, so he split the case to have a look inside. Wow, Ian has s KAAZ straight cut gear set! Everything was pretty worn including the input shaft where the seal rides, so the transmission will have to be revisited soon. Howard replaced the input shaft, tail shaft, and axle seals.

After changing the seals, the transmission case halves are coated with a sealant to be reassembled.

The transmission is reinstalled in reverse order of the removal.

With the new Exedy Stage 1 clutch and racing lightweight flywheel, we initially experienced a little chatter for a few hundred miles until everything broke in. After that, the clutch became buttery smooth with an OEM like pedal effort and engagement feel.  All of the slipping that was experienced before was totally gone.

For the 5 speed WRX with its weak transmission, this clutch is a very viable way to go and should take us through our anticipated engine rebuild and power mods. The tranny, however, is living on borrowed time. The worn gears and internals, and most bothersome- the grooved by the old seal input shaft, are worrisome. Although nothing leaks for now, we are afraid the leaking will return soon.

Instead of going the easy route and dumping in a strong STI 6-speed, we will be researching how to strengthen the 5-speed and getting it to live with a built engine and track use. It will be a long process, but stick with us- we will be getting Project Bugeye up to speed bit by bit!

Sources

Exedy

 

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