EA82 , box, clutch, pivot differences ? argh !

[jono]

As you may have read elsewhere, I am currently swapping an EA81 out of my Brumby, an EA82 going in, in front of an already fine running 5MT DR from an EA82 series.

 

Got no clutch pedal !!

 

Measured up against a running EA82 and the front face of the fork where the cable pulls is 105mm from the engine/box join in it.

 

The bad one is 118mm from the mating faces ! This is where my problem is.

 

Used a flywheel from a FWD EA82T XT Vortex - measures same thick at side edge as a known? 4WD EA82 flywheel

 

The pivots, are tricky to measure in box, think I found 4mm differencs, need to check this

 

Just how can matching components not match and cause this little grief ?

 

The clutch kit for EA82T FWD XT Vortex is same as regular 4WD EA82, EA82T

 

One part number for the forks for all of them.

 

Two part numbers for the fork pivots but the first was for 85 models, next for after 85.

I dont have any 85 boxes, it is a 92 L Series EA82 5MT DR, so would think al the same.

 

If I hhave measured odd size pivot , it was on a casing, may be older 85 ?

 

Looking to cut off the pivots stud, drill and tap, use spacers and a stud to get the fork out where it needs to be.

If the collective of USMB has no idea of the differences - we're all stumped

 

Further...

 

all the pivots are relatively same length now that I have a few out, just some have the tip flattened off to form a recess for grease - at one time

 

Fully installed, the pivot is about 45mm in from  the front face of the bellhousing

The tip end of the input shaft is about 40mm out from the bellhousing face

Measured up the clutch installed on the flywheel and found the top of the pressure plate is 20mm off the back of the ring gear, the clutch fingers just 1mm below the 300mm steel rule I used.

More later

Edited January 20, 2014 by jono

[MilesFox]

The FWD clutch disc should be a smaller diameter than a 4WD The step is different. The pressure plate is probably crammed up on the clutch fork. Is the engine 

[jono]

Normally, yes, but the XT/Vortex EA82T FWD is listed as using the 225mm clutch kit that is used in the 4WD EA82 ! It all looks correct, flywheel, pressure plate numbers all match up to other 4WD plates etc.

 

I did find a difference between clutch combo that came off old EA81 that was in and working, and an eg of what was screwed on the back of the crank.

 

Approx 4mm, used my starter motor spacer from the 5 speed behind EA81, slipped its 4mm under the EA82 flywheel sitting on concrete floor next to old clutch pack and things levelled out - light bulb moment then suggested 4mm packing behind the pivot should get me back to where I was - and got the 118mm down to 100mm, so 4mm better than a running L Series EA82 sedan GLTA.

.

I used an old head bolt washer - 3.9mm thick

 

Got some pedal now, but not the best, thinking it is a bit rude to fit EA82 donk, clutch, clutch cable, gearbox and rear diff and inner console, and let an EA81 clutch pedal do the same job. EA82 have a longer throw on their pedal so, next stop,squirm under dash 

Edited January 20, 2014 by jono