Exedy Clutch only lasting 50000 km’s

Submitted: Monday, May 10, 2010 at 09:06
ThreadID: 78352 Views:4091 Replies:5 FollowUps:5
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I am a little annoyed by the fact that I only got 50000 km’s out my Heavy Duty Exedy clutch when I got 145000 kms out of the factory clutch. I have had 2 workshops telling me the clutch is slipping and needs replacing.

Here’s what’s happened:
2 weeks ago I was towing a mates boat, the clutch pedal started getting loser and loser and was basically free hanging by the end of the trip except the last 2 inches. There was just enough left in it to change gears. Hours later we are back from fishing and the clutch problem has gone and the pedal has returned to normal, I am guessing there was a overheating issue?

A couple of days after a very strange intermittent noise has appeared from gearbox/clutch area it does not matter if it’s in gear or not. It’s sounds like a hydraulic type of noise and the best way I can explain it is probably the same sound as a worn out power steering pump, a soft humming sound. There is also a very strong clutch slipping smell when you pop the bonnet. I can’t feel the clutch slipping yet and it drives like normal. The fluid level is at the max mark and there’s no sign of leaking

Comments from the experts please
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Reply By: Member - Tour Boy ( Bundy QLD) - Monday, May 10, 2010 at 10:41

Monday, May 10, 2010 at 10:41
Sounds like the master cylinder is holding pressure. This is similar to resting your foot on the clutch pedal causing premature wear. I had a couple of trucks do the same thing even to a new clutch. When the pedal goes down as it has done, crack a line from the master cyl and see if it spurts out under pressure, if so the master cyl is the prob.

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AnswerID: 416090

Reply By: Sea-Dog - Monday, May 10, 2010 at 10:43

Monday, May 10, 2010 at 10:43
Has your clutch got a booster?

Could be that your booster is getting over vacuumed and causing the clutch to semi engage and overheating the thrust bearing...

That would account for a lot of your symptoms but it does sound a bit weird.
AnswerID: 416091

Follow Up By: Member - Troll 81 (QLD) - Monday, May 10, 2010 at 10:58

Monday, May 10, 2010 at 10:58
Yes it's got the booster
FollowupID: 686167

Reply By: ChipPunk - Monday, May 10, 2010 at 11:47

Monday, May 10, 2010 at 11:47
It's very unlikely to be a fault of the Exeedy - even their quality control seems quite successful in preventing manufacturing faults.

You do not mention clutch slippage?
Has there been a problem with the clutch itself?
If it is slipping, has it been sized to suit the max torque of your engine (in case your engine has been modified. Remember "clutch is torque" (twisting) to power output does not matter - only the peak torque)?

Your pedal description is that of faulty hydraulics - probably a slow leak which is not refilling (hence a loose pedal; the clutch disengages only near the floor - maybe then not fully hence certain gears are difficult).
It's quite likely a booster issue, otherwise the master cylinder.
Have them checked or re-kitted etc (master AND slave!)
I doubt that the fluid would be so old or get so hot as to vapourise.

The noise may be coincidental - unless the new clutch was incorrectly adjusted so that there is always pressure. This will wear the thrust bearing (which was replaced along with the clutch wasn't it?) and could account for the hydraulic failure you describe, as well as slippage if that did occur.
If the latter is the case, claim against whoever installed it.

Same if the clutch installation has damaged the front main bearing or impacted the input shaft and caused damage.
Maybe the flywheel (spigot) bearing needs replacing. I do mine whenever I replace the clutch.
AnswerID: 416101

Follow Up By: Member - Troll 81 (QLD) - Monday, May 10, 2010 at 12:40

Monday, May 10, 2010 at 12:40
There is no slipping that I can feel and it drives like normal

If I was losing fluid I would expect the level to drop but it's been at the same level for ever
FollowupID: 686174

Follow Up By: ChipPunk - Monday, May 10, 2010 at 16:58

Monday, May 10, 2010 at 16:58
You can have a leak without losing fluid - fluid bypasses main seals without passing the secondary or external seals.

But it can also be a sticky mechanism in the booster.

But if the clutch in not slipping, it is not a clutch problem - as in not clutch, pressure plate etc. This does seem more like an actuator problem.
FollowupID: 686214

Follow Up By: Member - Troll 81 (QLD) - Monday, May 10, 2010 at 17:16

Monday, May 10, 2010 at 17:16
I took it down to a clutch and gearbox place at lunch and the fella there doesn't think it's the clutch itself he said it feels like the booster is not working at all and the noise seems to indicate hydraulics. The thurst bearing and all the other bits was replaced at the time the new clutch went in. He said just keep driving and see what happens
FollowupID: 686219

Reply By: Roughasguts - Monday, May 10, 2010 at 12:24

Monday, May 10, 2010 at 12:24
Have you checked the hose from the master to the clutch?
It could be kiinked trapping the Brake fluid down the bottom end, then putting pressure on your clutch causing it to slip, then boil the fluid out hence the spongy pedal when hot.
AnswerID: 416106

Follow Up By: Member - Troll 81 (QLD) - Monday, May 10, 2010 at 12:40

Monday, May 10, 2010 at 12:40
I have not but will check tonight
FollowupID: 686175

Reply By: Michael ( Moss Vale NSW) - Monday, May 10, 2010 at 17:27

Monday, May 10, 2010 at 17:27
There has been many Patrol owners that have replaced their original clutch with another Nissan clutch. Mostly because they got a very good run out of it. My 2003TDI will roll over 300,000ks this week with the original clutch. I need at some stage to change it and i will be buying an original setup.. And its only about $500 for all the bits, i believe.. regards Michael.
P.S. My clutch is running fine but when do i replace it?? decisions, decisions!!!
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