The following is a cut/paste from a thread over on TI...by me of course. Quick background, my clutch went out on me a few nights ago out of the blue (as in, at a red light basically). Here's the damage.....

.........

Okay...the car is back...time to break in the new clutch. I didn't install an LSD because of the cash situation unfortunately...in fact, don't expect me to buy anymore parts for the car awhile. I know I had plans to upgrade the valvetrain and such in the next few months, but that must be put on hold......for awhile.

Okay....so it appears that one of the springs on the disc popped out. Why it popped out? ...not sure exactly. I wasn't beating on the car at all when it happened.

So...here are the pictures...


That's the pressure plate.


There's the old disc...with the spring that busted out in the middle. The spring did some damage to the flywheel and the disc.


just a close-up...


You can see various damage here.


This one is crucial...this is the other side of the disc (attaches to flywheel). Notice the gashes from the loose spring.

Okay...onto the Jun Ultralight flywheel damage...


Just an overview shot, you can see the multiple hot spots on it...not good.


more hot spots


more hot spots on the other side...also some teeth damage.

If you're not familiar w/it, the Jun/Zex flywheels (same thing) have a history of grinding on the starter once in awhile. Here's some first-hand evidence...


Yes...those are HUGE gashes in the teeth.


And more gashes...argh!

I've been told multiple ways to avoid this teeth problem, such as...regrinding the starter to fit (unless it's too worn already), regrinding the teeth on the flywheel, or use a JDM B16 starter (same starter came on Si in the states apparently). For now, the starter was regrinded...so far, so good, but who knows.

And that's the damage...however, the car seems to be running fine right now. Hopefully it stays that way.

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Fluid levels were good, but there was a slight from the rear main seal...but I can't see it causing this. The clutch was an ACT HDSS.

Thoughts and comments are welcome...

 

whoa..thats pretty intense

 

How many miles did you have on it???

 

I feel for ya man, same thing happend to me. Over $800 in repairs. Goodluck

 

have you considered resurfacing the flywheel? or did you just drop it in again as-is?

jun flywheels are NOTORIOUS for giving problems to USDM starters... if you had the cash i'd suggest going with an exedy but thats not the case... good luck, hope the new setup is a lil more forgiving.

did you put in another ACT? i'd avoid them after seeing something like that happen...

 

I've seen quite a few clutches pulled where the springs are loose like that. I know when I pulled my clutch two springs were about to come out of their housings. I wonder why that happens. Oh well...its a wear item anyway right?

 

get a unsprung disc if its happened so many times. lol i wonder if they make full face unsprungs.....

 

wow that sucks, talk to ACT and see what they can do about that ckutch damage....

 

I'm going to contact ACT soon and see what their view on this situation is. However, the damage has already been done, both to the car...and my wallet. I replaced w/another ACT because I already bought it basically. I originally thought the pressure plate went bad...but was in for a surprise when the tranny was off.

 

sorry to hear dude.

i've heard too many horror stories about ACT. had an exedy on my B18C-R hatch and it gave me no problems... maybe you can look into that one when this ACT goes bad as well

see if you can get some $$ back from ACT.... its worth a try...

 

I'm writing a letter to ACT today w/pictures included. I'll keep everyone posted as to what happens.