Problems clutch 450 / 0.6

[mottofreee]

I recently bought a Smart, 0.6 / 40kW but with problems.
Not engage in speed ,clutch kit was replaced with a new 1 year ago.
Taking down I found the cause - namely faulty clutch pressure plate tabs that hold the solar spring are broken - all 3.
https://plus.google.com/photos/11282...19251321894610
https://plus.google.com/photos/11282...18831510755506
After market ,made in China or something .
I will try to recondition it but I have no blades ...
During disassembly I found:
- Assisted braking valve broken and glued with cyanoacrylate;
- 1 hose Admin main air hose (air filter turbo) split;
- one from the hose connecting pipes are broken 80%;
- another connecting pipes repaired with epoxy resin.
- 1 reluctor split.

[tolsen]

Rebuild the clutch assembly with 3 equal length same dimension as original straps made out of 316 stainless steel. Stainless steels have much higher fatigue limit resistance (270 N/mm2 as opposed to about 150 N/mm2) than carbon steels and the bonus is they do not rust.
Cut suitable piece out of your kitchen sink while the wife is away.
Stress in the straps due to engine torque is not very high approximately 30 N/mm2 plus bending stress.

Main cause for clutch pressure plate straps failing is clutch engaging uncontrolled with a bang causing the engine to stall and car to jump forward. Usually caused by broken wires in lead to clutch actuator. Repair by soldering and applying heat shrink sleeves. Remember to use hydrochloric acid solution to clean black oxidized copper to bright metal.

[mottofreee]

He walked off place - that when he leaves, only sometimes ... anyway if clutch it's faulty not make an accurate determination.
A possible cause of failure is sudden departure -> clutch actuator or wires.
I clean them with wires salicylic acid (solid) or sodium persulfate (liquid). Also MRA223 etched or mechanically.
223 is for niceties (eg electronic) ...

Reluctor : https://plus.google.com/photos/11282...46132468722258
Valve : https://plus.google.com/photos/11282...46966014333010

[tolsen]

Is valve with broken barb from brake servo vacuum pipe or from upper breather pipe?

[mottofreee]

From rigid vacuum pipe (PVC). I will cut rupture and fix with a piece of rubber hose.

[ossy]

replace the broken 600cc clutch kit , for a 700cc clutch kit.
Then you have smoother gearchange !
Because of the weight difference.

[mottofreee]

I started working on the clutch and tend finish ; however , suggestion is to remember . If not influence dynamics the heavier flywheel?
I opened the rivets tabs (or ends) and now looking for suitable material for them - understand that stainless steel is recommended.
316 / 316Ti not know if it's hardenability but 309 (refractory) is recommended hardenability, high's mechanical stress conditions.
If I'm lucky, tomorrow find 309; if not, that would be variants (at Stainless Steel) ?

[tolsen]

Austenitic stainless steels have better fatigue strength limits than ferritic and martensitic steels. Therefore go for AISI 309 or 316. Check using your magnet.

[mottofreee]

I have not found 309 or 316.
I procured a band saw for cutting metal http://www.mkmorse.com/products/index.aspx?product=47 ,1mm thick that I made the 3 fishplates :
https://plus.google.com/photos/11282...14616007357906
Not satisfied with them, tomorrow I have to manufacture other straps ,more accurates.

[tolsen]

You bought brand new blade? I have loads of broken band saw blades.

[mottofreee]

Broken .
Bimetal but I'm interested in than by blade ,teeth ...

[mottofreee]

I started the engine clutch fitted and working correctly.
https://plus.google.com/photos/11282...29856420306818
For clutch mounting ,must be grinding a key ring elbow 17. https://plus.google.com/photos/11282...27561619504162
It is suitable and for fitting clutch 450 CDI on engine .
I remain test of the road, expect delivery reluctorul and curing turbo hose.
https://plus.google.com/photos/11282...28440878789266
https://plus.google.com/photos/11282...29259018888802