installed ap1 flywheel, oem disc, and ACT HD pp
the starter is fried..and i got a new one shipped overnight..i asked him what caused it to fry and he said "idk"..ghetto a** mechanic! lol..
if the new starter won't start still, he said he had to drop everything again and check it...! which mean more waiting time for me...sux...
If the flywheel caused it you'll think the flywheel/clutch is messed up now or he just need to realign everything?
btw- i'm so anxious to put my KW hi boost kit..and this guy is holding me back...i'll be putting this one myself btw...i trust myself more than that guy..lol..i just didn't have the tools/lift for the clutch install...
if the new starter won't start still, he said he had to drop everything again and check it...! which mean more waiting time for me...sux...
If the flywheel caused it you'll think the flywheel/clutch is messed up now or he just need to realign everything?
btw- i'm so anxious to put my KW hi boost kit..and this guy is holding me back...i'll be putting this one myself btw...i trust myself more than that guy..lol..i just didn't have the tools/lift for the clutch install...
I'm thinking the clutch is engaged or seized...
When you install the new starter... just try starting the car once. If all you hear is a click STOP immediatly or your going to fry another one.
IF anything i would ask for him to tear it down and make sure everything looks ok before going any further. A clutch install is pretty simple... so he should be able to find what the problem is when he looks inside. I'm sure its something simple.
When you install the new starter... just try starting the car once. If all you hear is a click STOP immediatly or your going to fry another one.
IF anything i would ask for him to tear it down and make sure everything looks ok before going any further. A clutch install is pretty simple... so he should be able to find what the problem is when he looks inside. I'm sure its something simple.
I agree with kix. Clutch install is a bit of a pain, but nothing exotic. After reinstalling, but before hitting the start button, try rotating the crank via the crank pulley bolt (be sure to have the transmission disengaged). You should be able to turn it. If you can't, don't even bother using the starter.
Originally Posted by 73Zero,Oct 23 2008, 09:17 AM
Hilarious.Anyways, I'd start with the basics. Pull the starter and have it tested...you mentioned that you saw smoke coming from it, so I'm thinking it could be fried.
Does your mechanic have a service manual for our S2000? 'cause replacing the clutch on our car are pretty complicated without the service manual. When I did my car's clutch my best friend is my service manual and my tools.
He probably torqued the hell out of the clutch when he tightened down the PP. Those bolts are in a specific sequence to a specific torque spec (I think its only like 16#ft). If you over tighten, it will press the clutch disc into the flywheel, effectively engaging it (or so it seems from what I have seen when replacing mine, when looking at it.
But then again, I am no mechanic.
I recommend printout this (its a DIY that was posted):
And ask if he followed it in terms of install. He can at least use it as a troubleshooting device.
Bottom line it, it was working before it came in, and a clutch change should not fry a starter. You should not be out any more $ than the cost of the original install.
You can download the OEM S2000 repait manual free, just google search for it. You can get the torque specs for each bolt on the flywheel / pressure plate, so he can verify that as well.
Did you re-use the old OEM throw-out bearing? Or a new one?
John
But then again, I am no mechanic.
I recommend printout this (its a DIY that was posted):
Ill start under the hood by doing these in this order:
Tools: 12mm,10mm,14mm combo wrenches, 10mm,12mm,14mm sockets
14mm flex socket, 24"12" extensions, ratchet wrenches, a long handle makes it real easy to
loosen the tensioner. +/ - screwdrivers, torque wrenches, clutch alignment tool. Flashlight.
1 Remove air box, 10mm heads / Battery terminals 10mm stubby wrench
2 Accessory belt, 14mm head on a breaker bar for the tensioner
3 Heat shield on manifold, 12mm heads (I say heads because the threads are stated in manual)
4 Battery heat shield, 10mm Last bolt just loosens
5 Alternator top bolt out, loosen lower, 14mm
6 A/C pump bolts loosen 2x 14mm on top, remove forward most top bolt, disconnect wire from under car later
7 Disconnect two sensor plugs on head by the firewall
8 Disconnect vacuum hose (the one shown in manual at rear of head ((suction valve))
9 Mark steering joint, and remove 10mm bolt at front (other bolt loosened later)Make sure steering wheel is locked straight.
10 Swing alternator out a bit to get to upper starter bolt, 14mm remove but leave bolt resting on alternator,
YOU WILL WANT A 14mm FLEX SOCKET . . . + about 24" of extension, I recommend using duct tape so you wont drop the socket amid all the hoses and wires. You get at this bolt from an angle, and directly between the throttle body and alternator.
11 Disconnect power steering connectors, one big and one small (electrical)
12 Loosen exhaust manifold bolts at head 12mm (Keep Snug)
13 Remove 14mm bolt at rear of intake manifold, wiring harness support bar
14 Raise car, I recommend at least 24" clearance at body jack points. I managed to get here in 18 min.
When under car you will want these
10mm combo wrench, I use a gearwrench
12mm,14mm,17mm combo wrenches
12mm deep,12mm,14mm, 17mm socket, 6mm hex socket (short as possible)
24" and 12" extensions you'll need at least 36" for the top tranny bolts
Small crook needle nose pliers for removing plastic snap in wire holders
Ratchets, 3/8" and 1/2" drive with 1/2 to 3/8 adapter
Impact wrench with 17mm, 19mm deep sockets or short extension.
1 Remove splash shield
2 Remove front engine bump stop (I just leave mine off now)
3 Loosen rear steering joint bolt and slide joint back to disconnect, 10mm
4 Disconnect A/C wire and remove remaining bolts from pump (3)
5 Remove cable ground wire to engine block
6 Remove 14mm bolt on lower wiring harness support bar
7 Remove clutch slave cyl. 12mm open end wrench
8 Disconnect 02 sensor connectors, and tranny wiring harness
9 Remove cat. conv. use the deep 12mm socket and box end 12 wrench for the front two, 14mm combo for the rear
10 Loosen 3 lower driveshaft bolts(on each end), 6mm hex, if you cant get the wrench in there, remember the
shaft slides on cv joints. Parking brake should be on.
11 Remove 14mm bolts on exhaust manifold support, remove manifold. When your're up top again to remove
the manifold nuts, release the parking brake, and remove the shifter knob/lever. 10mm heads
12 Remove 19mm subframe bolts (The middle ones that come out)
13 Turn driveshaft 180*
14 Remove bolts that connect shifter box to tranny tunnel, 10mm
15 Loosen lower tranny to engine bolts, 14mm/17mm
16 Put the brake back on, then loosen the other 3 driveshaft bolts (each end) Mark driveshaft if it is not yet, and remove.
Now its time to support the subframe, I just use a 24" 2x4 on a jack placed under the front beam and the oil pan.
when supported, back out the front subframe bolts 3" (19mm) and the rear subframe bolts 3" (17mm)
When the subframe comes down a bit you can see exactly how for to back out the bolts by looking at the gap in the
threads.
With the subframe lowered and supported by the bolts you can now get to the top tranny bolts. (17mm)
Support the tranny and remove the 3 tranny crossbeam bolts at rear, remember to pull out the release fork
so the tranny will come all the way off the engine.
For the clutch you will need 12 point sockets, 10mm for the pressure plate, and 17mm for the flywheel.
I'll undo the PP bolts just by hand in a crisscross pattern, they aren't that tight. For the flywheel bolts,
I'll zip out those with a low power impact wrench so I don't need a flywheel holder. If you have a Toda
flywheel, you can use a 14mm deep socket through those holes to hold the FW. If not you can use a big
screwdriver or prybar to hold the starter teeth on the FW. When putting the tranny back in, remember to
have to alignment pins in place, and that perfect alignment between tranny/engine is just as important
as a clutch alignment tool. It will slip right on
When putting the cat back in, it will be good to leave the exhaust man. loose, sometimes it's a tight fit with
aftermarket cat-back systems.
The plastic white ring around the inner shift boot comes out a special way, you will see little arrows that
point to where the barbs are. Take a small but long flat head screwdriver and insert just inside the ring
through the hole in the rubber boot while lifting on the boot at the same time.
I have found that the clutch change has a negligible effect on the front end alignment.
Remember this is my quick way of pulling my tranny, I may have left something out, so double check with
the manual before starting. So there you have it, and I'm going out in a few to do it again . . .
OH yeah, none of my clutch discs have exhibited any undue wear, just a bit of scorching - so you may be better off with an OEM disc and a heavy duty PP. Im working on the noise thing, with interesting results.
Tools: 12mm,10mm,14mm combo wrenches, 10mm,12mm,14mm sockets
14mm flex socket, 24"12" extensions, ratchet wrenches, a long handle makes it real easy to
loosen the tensioner. +/ - screwdrivers, torque wrenches, clutch alignment tool. Flashlight.
1 Remove air box, 10mm heads / Battery terminals 10mm stubby wrench
2 Accessory belt, 14mm head on a breaker bar for the tensioner
3 Heat shield on manifold, 12mm heads (I say heads because the threads are stated in manual)
4 Battery heat shield, 10mm Last bolt just loosens
5 Alternator top bolt out, loosen lower, 14mm
6 A/C pump bolts loosen 2x 14mm on top, remove forward most top bolt, disconnect wire from under car later
7 Disconnect two sensor plugs on head by the firewall
8 Disconnect vacuum hose (the one shown in manual at rear of head ((suction valve))
9 Mark steering joint, and remove 10mm bolt at front (other bolt loosened later)Make sure steering wheel is locked straight.
10 Swing alternator out a bit to get to upper starter bolt, 14mm remove but leave bolt resting on alternator,
YOU WILL WANT A 14mm FLEX SOCKET . . . + about 24" of extension, I recommend using duct tape so you wont drop the socket amid all the hoses and wires. You get at this bolt from an angle, and directly between the throttle body and alternator.
11 Disconnect power steering connectors, one big and one small (electrical)
12 Loosen exhaust manifold bolts at head 12mm (Keep Snug)
13 Remove 14mm bolt at rear of intake manifold, wiring harness support bar
14 Raise car, I recommend at least 24" clearance at body jack points. I managed to get here in 18 min.
When under car you will want these
10mm combo wrench, I use a gearwrench
12mm,14mm,17mm combo wrenches
12mm deep,12mm,14mm, 17mm socket, 6mm hex socket (short as possible)
24" and 12" extensions you'll need at least 36" for the top tranny bolts
Small crook needle nose pliers for removing plastic snap in wire holders
Ratchets, 3/8" and 1/2" drive with 1/2 to 3/8 adapter
Impact wrench with 17mm, 19mm deep sockets or short extension.
1 Remove splash shield
2 Remove front engine bump stop (I just leave mine off now)
3 Loosen rear steering joint bolt and slide joint back to disconnect, 10mm
4 Disconnect A/C wire and remove remaining bolts from pump (3)
5 Remove cable ground wire to engine block
6 Remove 14mm bolt on lower wiring harness support bar
7 Remove clutch slave cyl. 12mm open end wrench
8 Disconnect 02 sensor connectors, and tranny wiring harness
9 Remove cat. conv. use the deep 12mm socket and box end 12 wrench for the front two, 14mm combo for the rear
10 Loosen 3 lower driveshaft bolts(on each end), 6mm hex, if you cant get the wrench in there, remember the
shaft slides on cv joints. Parking brake should be on.
11 Remove 14mm bolts on exhaust manifold support, remove manifold. When your're up top again to remove
the manifold nuts, release the parking brake, and remove the shifter knob/lever. 10mm heads
12 Remove 19mm subframe bolts (The middle ones that come out)
13 Turn driveshaft 180*
14 Remove bolts that connect shifter box to tranny tunnel, 10mm
15 Loosen lower tranny to engine bolts, 14mm/17mm
16 Put the brake back on, then loosen the other 3 driveshaft bolts (each end) Mark driveshaft if it is not yet, and remove.
Now its time to support the subframe, I just use a 24" 2x4 on a jack placed under the front beam and the oil pan.
when supported, back out the front subframe bolts 3" (19mm) and the rear subframe bolts 3" (17mm)
When the subframe comes down a bit you can see exactly how for to back out the bolts by looking at the gap in the
threads.
With the subframe lowered and supported by the bolts you can now get to the top tranny bolts. (17mm)
Support the tranny and remove the 3 tranny crossbeam bolts at rear, remember to pull out the release fork
so the tranny will come all the way off the engine.
For the clutch you will need 12 point sockets, 10mm for the pressure plate, and 17mm for the flywheel.
I'll undo the PP bolts just by hand in a crisscross pattern, they aren't that tight. For the flywheel bolts,
I'll zip out those with a low power impact wrench so I don't need a flywheel holder. If you have a Toda
flywheel, you can use a 14mm deep socket through those holes to hold the FW. If not you can use a big
screwdriver or prybar to hold the starter teeth on the FW. When putting the tranny back in, remember to
have to alignment pins in place, and that perfect alignment between tranny/engine is just as important
as a clutch alignment tool. It will slip right on
When putting the cat back in, it will be good to leave the exhaust man. loose, sometimes it's a tight fit with
aftermarket cat-back systems.
The plastic white ring around the inner shift boot comes out a special way, you will see little arrows that
point to where the barbs are. Take a small but long flat head screwdriver and insert just inside the ring
through the hole in the rubber boot while lifting on the boot at the same time.
I have found that the clutch change has a negligible effect on the front end alignment.
Remember this is my quick way of pulling my tranny, I may have left something out, so double check with
the manual before starting. So there you have it, and I'm going out in a few to do it again . . .
OH yeah, none of my clutch discs have exhibited any undue wear, just a bit of scorching - so you may be better off with an OEM disc and a heavy duty PP. Im working on the noise thing, with interesting results.
Bottom line it, it was working before it came in, and a clutch change should not fry a starter. You should not be out any more $ than the cost of the original install.
You can download the OEM S2000 repait manual free, just google search for it. You can get the torque specs for each bolt on the flywheel / pressure plate, so he can verify that as well.
Did you re-use the old OEM throw-out bearing? Or a new one?
John
Overtightning the PP bolts will do nothing but shear them. The are on two faced up surfaces so they wouldn't cause any serious warpage. I'm thinking the mechanic forgot the top bolt and something moved.
the starter is replaced and the car started no problem...and the clutch feels a little stiff, but in the long run i'll get use to it..thanks for you'll responses...
i just finished installing the KW hi boost kit..took me 3 days along with my friend's help..hopefully i'll be getting the ECU tomorrow and crank it up..hoping there's no leak or anything..i'm sure i tighten everything but i won't know til tomorrow..can't wait..
i just finished installing the KW hi boost kit..took me 3 days along with my friend's help..hopefully i'll be getting the ECU tomorrow and crank it up..hoping there's no leak or anything..i'm sure i tighten everything but i won't know til tomorrow..can't wait..








