Exedy Clutch only lasting 50000 km’s

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.

Cheers
Dave

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.

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.

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.

Troll!!
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!!!