<div dir="ltr"><div>My first thought was that if you were having to force the gearbox when it was 3 to 4 inches away from home, it may be the spines in the clutch disc and the input shaft were causing some interference. This should have been an easy slip fit. Did you lubricate the spines? Test fit the disc on the input shaft? Installing a gearbox should not be a tedious affair. Or, you did not get the disc properly aligned using the little plastic tool. There is a lot of wiggle room for error. I've found that an old input shaft works better than the plastic ones for getting good alignment. <br></div><div><br></div><div>That brings me to my next observation. If for some reason the clutch disc is hanging up on the input shaft it will not disengage as smoothly as it should. Is this your problem? It's not clear to me what you mean when you say "difficult clutch".<br></div><div><br></div><div> I have never heard of any need to break-in a clutch.<br></div></div><br><div class="gmail_quote"><div dir="ltr" class="gmail_attr">On Sun, Sep 19, 2021 at 2:15 PM Michael Oritt via Healeys <<a href="mailto:healeys@autox.team.net">healeys@autox.team.net</a>> wrote:<br></div><blockquote class="gmail_quote" style="margin:0px 0px 0px 0.8ex;border-left:1px solid rgb(204,204,204);padding-left:1ex"><div dir="ltr"><div class="gmail_default" style="color:rgb(51,51,255)">Simon--</div><div class="gmail_default" style="color:rgb(51,51,255)"><br></div><div class="gmail_default" style="color:rgb(51,51,255)">I cut the head off one bolt to make it easier to R&R the secondary cylinder. I also fashioned a small door in the extension panel to give access to the bleed nipple from inside rather than only under the car.</div><div class="gmail_default" style="color:rgb(51,51,255)"><br></div><div class="gmail_default" style="color:rgb(51,51,255)">Best--Michael Oritt</div></div><br><div class="gmail_quote"><div dir="ltr" class="gmail_attr">On Sun, Sep 19, 2021 at 4:23 PM Simon Lachlan via Healeys <<a href="mailto:healeys@autox.team.net" target="_blank">healeys@autox.team.net</a>> wrote:<br></div><blockquote class="gmail_quote" style="margin:0px 0px 0px 0.8ex;border-left:1px solid rgb(204,204,204);padding-left:1ex"><div lang="EN-GB"><div><p class="MsoNormal">You’ll recall the Overdrive saga. Have decided not to commission a TV mini-series per someone’s advice.<u></u><u></u></p><p class="MsoNormal">1) The overdrive is in and works very well. I haven’t tested the pressure yet – I will – but it clicks in and out very briskly.<u></u><u></u></p><p class="MsoNormal">2) The new clutch kit is in. Hard to get the old bits off until I borrowed that magic tool. Used the black nylon(?) tool from AHSpares as so much handier than the spare original shaft. <u></u><u></u></p><p class="MsoNormal">3) Putting the gearbox back in was pretty tedious. It would go in all the way except for the last 3 or 4 inches. Took it out again and checked the alignment was 100% which it was. Put it back in, pushed, shoved and cursed. In the end we wound it on with long threaded bolts. I don’t want to put in another clutch. Ever.<u></u><u></u></p><p class="MsoNormal">4) Now, finally, the QUESTIONS:-<u></u><u></u></p><p class="MsoNormal">Initially, getting the car into any gear was very graunchy and really the car would have been undriveable. Pedal pressure felt the same as before but nothing was happening except expensive noise. <u></u><u></u></p><p class="MsoNormal">Although there was no evidence of a loss of fluid – why would there be? – I bled the clutch. I have fitted the extension tube so it wasn’t tricky. That did make a difference but not to the way it was previously.<u></u><u></u></p><p class="MsoNormal">So (1) Is it normal for clutches to be difficult at first? A sort of “breaking-in” period??<u></u><u></u></p><p class="MsoNormal">(2) I’ll bleed it again but am drawn to getting a longer push rod for the slave cylinder. Does that make sense? I do have to push the pedal down pretty far. Comments?<u></u><u></u></p><p class="MsoNormal">(3) Slightly off topic……digging around in my files, I saw a suggestion to cut the head off the top bolt that locates the slave cylinder. Then to Loctite in permanently for use as a dowel peg. ie that bolt is a bit of a PITA and one bolt would suffice. Wouldn’t it?? <u></u><u></u></p><p class="MsoNormal">All advice would be very welcome,<u></u><u></u></p><p class="MsoNormal">Simon<u></u><u></u></p><p class="MsoNormal"><u></u> <u></u></p></div></div>_______________________________________________<br>
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