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Can't always select reverse after new clutch fitted


grumpy the 7th

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At the end of a most enjoyable 3 week 1700 mile trip last May to Orkney and Shetland the clutch gave way at the top of Shetland (I couldn't select any gears although there was pressure on the clutch pedal when pressing and the fork was moving back and forth in sync with the pedal movement) and necessitated RAC recovery to a garage with plenty of Caterham experience of my choice in South Yorkshire.

The garage could not source from anywhere a standard Caterham K series clutch so replaced it with a complete Helix clutch part no. 1605 (https://www.demon-tweeks.com/uk/helix-190mm-organic-sprung-drive-plate-hlx70-1605/) along with CRB, cover, water pump and timing belt.

Two days later we embarked on another 3 week 1600 mile trip along all of the Outer Hebrides islands without any hint of a problem. (This new clutch was "run in", in accordance with the recommended procedure ie; NO track and no racing starts for 500 miles) So 350 miles to Oban and certainly no thrashing around any of the islands! and back home. It's been problem free since June.

Until last week when we went to North Yorkshire for a 4 day tour and when parking up at the pub on the first night I couldn't engage reverse, even after trying neutral. It eventually went in with some clunking!!!

I gave the clutch cable some adjustment to give more clearance between the plates with the biting point almost at the top of the pedal travel. This appeared to work OK on the the next morning but after the car was warm (NOT as in thrashed hot) I couldn't get reverse without some clunking. This happened all 3 days. It seems OK when cold but even when only normal road use hot it won't engage.

I 'HOPE' I can't imagine the clutch is the problem ??

I will replace my Redline MTL 50k miles old with new Redline MTL although I don't susspect this. (the level was checked OK at last April's service).

1ClutchPlate.thumb.jpg.f673e67bed8d303c337ecbf0d2772806.jpg  Damagecloseup1.thumb.jpg.07480bcbfc7e97afd0542503ae0f45c3.jpg  Damagecloseup2.thumb.jpg.cce5cf88173394d1b4cfe5a5642bb607.jpg

2xNondamaged.thumb.jpg.c6bf8dbf2fa39e762eb4d739a655b36c.jpg The recovered plate shows damage to 2 of the springs along with damage to both raised lips holding the springs. The opposite springs and housings are not damaged. In reality the garage suggested that there should be no reason why I couldn't get any gears as the plate is still intact. 

Everything's been OK for about 2000 miles until this.

Any body got any suggestions please?

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I was helping a club member with gear selection problems on their newly rebuilt engine (at some expense at a renowned engine builder)

On disassembly, I found the friction plate had been fitted the wrong way around :-0.

The engine company paid for a new clutch as this had been part of the build and balanced with the flywheel!

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Can't think, (hope) the plate is the wrong way round as it was a Caterham friendly garage. Clutch cable is very smooth and NO I don't know what caused the damage to the original plate. Gear changing became impossible after stalling the car doing an abrupt stop when a car cut in front of me. Couldn't get any gear for a panicky few seconds then got forward gears but no reverse. So assumed the clutch had broken some springs but as you can see they're ok albeit 2 are scraped. But on what we don't know.

The difficult reverse problem only came on after some 2000 miles and 3 months after the new clutch was fitted. So something has happened to cause the difficult reverse problem. BUT only when hot.

I've ordered some Coma 75/90 GL4 fully synthetic MTF (a bit thicker but doubt this will cure it) I've already drained the box and the 50k miles old Redline MTL 75/80 that came out was lovely and clean.

The gear lever seems fine and easily springs back to the 3/4 mid position from either of 1/2 or 5/6 gear positions. No noticable play in it and the lever pushes down easily to the left to select reverse (when cold or not running).

Hopefully the oil will come tomorrow so I can try the car.

thanks, rog

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