The Derploader

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They said since it was a direct OEM from GM that its out of their hands. While that sucks, I understand their policy from a business standpoint.

After a little more testing with the stock one in, I'm even more confident that the last slave was definitely fuq'd.

Time will tell though.opcorn:

And yes at point I can pull the trans is 30 min and just throw all 40 bolts in a bucket and not wonder which one goes where.

 

[$ub$onic]

And you wonder where the last two go

 

[Preloader]

Slave is bad again!!!!

Hahaha, I can't win!

I'm running out of ideas. I have one left though. Fingers crossed.

 

[$ub$onic]

Damn that sucks

 

[Insanika]

Fingers crossed.

+1

 

[ThatTmoGuy]

is there a reservoir for the slave?

 

[Preloader]

Clutchmasters is on the case. Either the friction plate is too thick or the pressure plate disc is too thick, causing too much travel range for the slave.

:-/

 

[ThatTmoGuy]

Trendsetter problems!

 

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I plan to take a time lapse video of the 4th and final R&R. It'll be fun to watch 90 mins in 30 seconds.

 

[ThatTmoGuy]

I'm sure you can get it down to 45 min now.

 

[theenico]

Is it possible that the binding encountered in round one might have cooked the original slave?

Feel free to call if needed. Use the 620 number I PM'ed you.

 

[GeneralZod]

Is it possible that the binding encountered in round one might have cooked the original slave?

Feel free to call if needed. Use the 620 number I PM'ed you.

I was thinking the same thing after the first one gave up the ghost.

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With you trendsetting, CM should acknowledge your sacrifice as a test mule. Since they are backing you so far, think of what can be gained with your efforts. Track tested and DIY install with large gains. Think they should sponsor you or something to that level.

 

[Preloader]

Well, what is vexing is that they got it right with Swordsmiths kit already. The only difference is that I went for the 11lbs flywheel instead of the 13 lbs. and I went with a rigid disc, but CM swears that the dimensions are the same.

They are looking into my issue, but at this point I'm convinced its a discrepancy with the thickness of the flywheel or the step up from the face to the mounting surface where the pressure plate mounts.

The current plan is to (Monday) remove the new set-up and compare it to the stock set-up on the bench. With a mic/dial if something obvious doesn't reveal itself to the naked eye.

Although this process has been frustrating, I now have literally interacted with every bolt under my hood aside from major engine components. I enjoy knowing every detail of a car, it helps graduate me from a novice when it comes to the Sonic.

 

[Eric Smit]

yeah, get intimate under the bonnet.

 

[GeneralZod]

Well, what is vexing is that they got it right with Swordsmiths kit already. The only difference is that I went for the 11lbs flywheel instead of the 13 lbs. and I went with a rigid disc, but CM swears that the dimensions are the same.

They are looking into my issue, but at this point I'm convinced its a discrepancy with the thickness of the flywheel or the step up from the face to the mounting surface where the pressure plate mounts.

The current plan is to (Monday) remove the new set-up and compare it to the stock set-up on the bench. With a mic/dial if something obvious doesn't reveal itself to the naked eye.

Although this process has been frustrating, I now have literally interacted with every bolt under my hood aside from major engine components. I enjoy knowing every detail of a car, it helps graduate me from a novice when it comes to the Sonic.

Yeah read Swordsmith's trans upgrades. You really can't base it off of that. Going with the route you went, some of the physics change. When you measure everything I hope you find something. Other causes could be more troublesome. Things like expansion from heat, angular momentum, and a handful of other unforeseen consequences. I would even check how balanced or how level the the items are. I suspect if you threw on a 13 lbs flywheel it might end up working out.

That may apply only if the slave wasn't toast beforehand and all the parts measure true.

 

[Preloader]

This last time the slave blew it was my original slave that came with my car. It worked trouble-free for 12k stock miles, and then extended passed its seal in less than 5 miles with the new clutch/fly.

It is my understanding that the TOB (throwout bearing) will easily pop of the plunger seal (a bad thing) when it's travel isn't limited by the end range of a pressed in pressure plate.

If the CM pressure plate is indeed the same dimensions of the stock, which I believe it is (it appears they build them from stock cores), then the flywheel is too shallow.

In otherwords, by the time the TOB bottoms out the pressure fingers, it should not be so close to the slaves limit of travel. I've operated my slave, tens of thousands of times when everything was stock, and there was no risk of blowout because the thickness dimension of the stock fly/clutch/pressure plate limited the TOB from overextending.

tl;dr- yes, it appears the flywheel is the logical explanation at this point.

 

[theenico]

Looking at the pictures you sent me, I would say that the pressure plate is indeed just a beefed up LuK core. Because of this, I too now suspect a dimensional discrepancy in the flywheel itself.

 

[Preloader]

Ha, I looked at those pictures last night for an hour. Particularly comparing the CM pressure housing against the stock one and it DOES appear that they use core parts and an identical fulcrum point.

So it kind of stands to reason that the only variable left is the effect of the overall stack height caused by the flywheel.

I'm still gonna pull it Monday so I can have ammo when I call CM, but I'm feeling confident that once they get me the correctly gauged flywheel, and another slave replacement, my problems will be solved.

 

[GeneralZod]

Yeah, pretty familiar with the manual trans setup. I am focusing on the flywheel, it always tends be the issue when going for weight reduction. There always seems to be a limit to that reduction with some of the reasons I mentioned.

Your first slave lasted longer I think. Do you know the grade of the material used for the flywheel? I know I am getting nerdy, but I suspect a few issues with the flywheel are causing this.

 

[Preloader]

I never got to drive it long enough for heat to really become a factor. Also look at Sword, he has an aluminum fly from the same builders and has had many trouble-free miles (from the clutch).

I'm not hellbent on needing an aluminum one, or *sigh* even a lighter one than stock. But I absolutely require that I not use the retarded dual mass dampening stock edition. If you haven't seen it, watch this video:


CM tells me they have a stock fly on their bench for measurements, so I think I'll ask them to whip up a 13-pounder of identical dimensions and give it another go.