The flywheel bolts are 9mm 1.0 thread. So if I want to chase those threads I need to order the tap over the internet.
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Dave, that's right. I remember one of the 2 being a rare size. It was the 6 M8x 25mm pressure plate bolts ( 102593 ) I replaced.
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I have not decided if I will wait. I did finish installing the master and need to do some odds and ends on the transmission (one mount bolt was tight removing so need to chase those threads). I bought two long bolts and will cut the ends off to use as a guide when installing the transmission. I also noted the drivers side rear cam plate looks like it's leaking some oil so may pull that off and reseal it (I guess it's just a cover plate). Those things are easy to get to with the transmission remove and car up on blocks.
I'm still concerned I did not find what caused the problem. I plan to do a drive half the distance where it acted up and then return home so if it still has the problem I won't need a tow.
Turns out that tight bolt on the transmission is because someone tightened the back cover on the transmission before all the bolts were installed. So the bolt hole is rubbing on the bolt.
I forgot to mention that my problem was defiantly not caused by not enough clutch pedal travel. It's easy to see when you pull the pin off your clevis to the master. Mine has about 3/4" of extra travel.
I removed that cam cover plate that was leaking oil. Looks like they used red locktite on the two 6 mm bolts holding the cover on so I could not tell if the bolts were actually tightly bolted down. I could see where the oil was leaking on the cover plate. I chased the threads holes and I think the holes are open to oil since the tap went in about 3/4" so I will use a sealer on the bolt threads.
I think you would have to have the transmission removed or the head pulled to access that cover plate.
Maybe that is the only cause of the oil leaking on the rear of the engine.
I finished installing the cam cover. Made a new gasket and used Permatex sealer.
I installed the slave, fork and throwout bearing. By the way the new throwout bearing looks constructed better than the one I removed. Only marking on the new bearing was "Valeo".
I noticed a little bend in the rod that connects the slave push rod to the fork. Don't think it enough to replace it. But what would have caused that. My guess is only if the clutch had to much throw and it bottomed out. Not sure if I ever push the clutch peddle to the floor.
Every thing is ready to go back in after I get my 9mm tap to chase the flywheel bolts. I do need to rebuild one axle which can keep me busy for another day or two.
I should have checked my mail box yesterday. My taps were waiting for me. Amazed I ordered them on Saturday and they arrived on Monday. However the taps were a little to large for me to chase the threads. OD on the tap was 0.0095" over the bolt OD and they started cutting metal so I decided not to chase the treads.
Got the flywheel, clutch plate and pressure plate mounted, blue locktite and torqued to spec. Now the heavy part of lifting the transmission and bolting in place.
It took 2.5 hours to push the transmission back under the car and get it back sitting on the jack. It just took a lot of wood blocks rocking the transmission back and forth to get it up high enough to slid it onto the jack. I need to center on the jack and then it's ready to push back onto the engine.