Prototype clutch install

[Swordsmith]

Installed the new clutch and flywheel from Clutchmasters this weekend.

Basic order of operations:

Remove battery box and starter
Disconnect all electric cables to transmission

Drain coolant
Remove heater core hoses
Disconnect Vacc hose to brake booster
Disconnect evap line to fuel on top of intake.
Disconnect fuel line (not needed on my install since my alcohol sensor add on made the lines long enough to stretch)
Remove transaxles

Remove rear transmission mount
Support radiator
Remove subframe

Support engine (note hammers used to prevent support from crushing car)

Remove port transmission mount
Disconnect slave cylinder hose
Lower engine leaving starboard side up, low enough to get clearance to remove transmission
Dismantle transmission

Remove clutch and flywheel

Fit new clutch and flywheel; note, works in only one of the six possible positions.

Bleed clutch. Note, prebleeding helps a lot here.
Reverse above order of operations

I think I have pics of most of the above, going to start sorting them and will edit into the post.

 

[Swordsmith]

Stats for the clutch

OEM clutch and (white) new clutch.

The OEM clutch tests out as delivering a maximum of 1200 lbs of clamping force. The upgraded clutch kit I installed delivers 1600 lbs of clamping force, which should suffice up to 400 horsepower.

I also installed a light weight aluminum single mass flywheel, going from the OEM 25 lb dual mass down to a mere 13 lbs. This should dramatically improve response time.

The kit is available in several different stages, I got the FX300, which they are recommending based on experience with similar sized vehicles in the past. There is also a (marginally cheaper) FX100, and (both same price as FX300) FX350 and FX400.

I believe BNR is arranging to carry these, so I don't want to push the actual manufacturer instead of a sponsoring vendor, but I will give you their contact info in PM if requested, until such point as that is all set up. I'll edit this line out when that happens.

 

[nocoolnames]

Great cant wait to see them!

 

[Swordsmith]

Report on performance of the new clutch goes here, will edit this out when the post is complete

There is a recommended break in period for the clutch, 500 miles of basic stop and go driving before putting any serious pressure or NLS driving on it.

During the break in period, driving somewhat gingerly, I can report that the clutch pressure feels the same, pedal is very responsive, action is even smoother than the OEM (I was warned it might seem jerky and require some learning time on my part to adjust; this doesn't seem to be at all true) The pedal action seems to start a little closer to the floor, things seem to grab a little more clearly, but I have experienced no learning curve at all.

Slammed up a few onramps since crossing the 500 mile break in line. It's good to be back to mistreating the poor Sonic. As with the softer driving, there's some improvement, but not remarkably so; driving hard or soft is still pretty much the same as it was, just a bit better... tons of fun. The main reason for me to do this install was for the Red Pill tune, but we're still fine tuning the Blue Pill (the base E85 tune.)


Too bad the tracks are closed for the season around here, but I have found a shop that rents Dyno time, I wish I'd done a baseline, but we'll get some numbers on the tricked out version at least.

(add)
Talked to the guy who built the clutch for a few minutes. He said all the rattles I described sound normal; the original flywheel is a dual mass, and very heavy, and it functions as a sound dampener. The gearing in the Sonic is relatively loose, but the dampening takes out the sound; with this lightweight single mass aluminum flywheel, the sound isn't damped down. He was concerned that it might be annoyingly loud, as it is on some bigger cars when they make this switch, but in my opinion it is not. This will be a YMMV for prospective buyers though, I enjoy the way it talks back to me without shouting, but if you want something as quiet as the stock version, this isn't it; maybe try the new clutch with the original flywheel.

Other than that, he was very pleased with my report, and plans to put out a press release shortly to offer it to the public.


(add) Chatter reduced somewhat over the 500 mile run. It's still present, but less of it, and quieter. I guess the wear in period was a good idea.

 

[law242]

Ill subscribe

 

[$ub$onic]

Me to

Sent from my SAMSUNG-SGH-I747 using Tapatalk 2

 

[sx sonic]

Awesome stuff SwordSmith, can't wait to get the full details of your install and review

Subscribed

-tyler

 

[ThatTmoGuy]

...Too bad the tracks are closed for the season around here, but I have found a shop that rents Dyno time, I wish I'd done a baseline, but we'll get some numbers on the tricked out version at least.

You could flash the stock Tune do a few runs and then flash the red pill opcorn:

 

[RS Turbo]

Great! Looking forward to seeing what the Red Pill will do.

 

[Tommyboy4725]

Awesome!

 

[sx sonic]

How much are they planning to sell the flywheels for?? And can/will they make a lightweight steel or alloy flywheel?