Ok, for those that met in ABQ this weekend you know my problem. I installed a new DXDRacing Stage 5 clutch and pressure plate about 2500 miles ago. It's been perfect up till the drive to ABQ. It has also been through 26 consecutive dyno runs with not one issue. My problem is my throwout bearing pops out after about 5 presses of the clutch pedal. I've tried everything I know to try to rectify this situation. The final step is to separate the tranny from the engine and see what is going on.
I've talked to DXDRacing and they say this is a known issue with the higher stage clutches and that they are working with Hyundai to get a better throwout bearing made. Unfortunately I've got no ETA on when that is going to happen.

So my questions to you are as follows:

Am I just SOL?
Anyone know of a higher than OEM quality throwout bearing I can try?
Anyone ever try tack welding the Throwout bearing to the pressure plate? Do you think its possible to figure out a way to install the bearing/pressure plate and clutch disk on the tranny then mate it to the flywheel?
Any other suggestions?

When the bearing is engaged the clutch works fine with smooth engagement and no slippage.

 

Try contacting Mad John. I am sure he knows of something higher quality than OEM or a suitable solution.

 

Does Mad John ever post anymore or is he primarily a PM and Email kinda guy now?

 

He posts occasionally. I think lately I have seen him in the shoutbox more though. Send him a PM he should answer.

 

your problem is you have too much power for your exhaust manifold. luckily for you i have the solution, just switch with me,haha.

Dave, yours is the first gk i have seen boosted and truthfully it looks like you did a 1st rate job, get that baby running better soon!

316 rwhp running E85 is nothing to lookover guys, sheesh.

 

Thanks, I pride myself in the fact that I did ALL the work myself. smile.gif

As far as the car running it runs perfect...just the dang minor clutch issue. wink1.gif

Its eating me up insdie that I have to pull the tranny again. A little harder with it all nice an pretty in the engine bay. I just hope DXD comes up with a solution to my problem.

 

instal la brand new bearing snap ring in the pressure palte, if DXD reused an old snap ring it might be one reason
at the same time, use a new OEM bearing from hyundai, never had problem with those

if you want to be 100% sure and be done with it,
get my push conversion kit, and use ACT clutch kit for a non turbo DSM
turbo DSM cluthc kit can be used, but you'll need to modify your flywheel

 

Thanks Denis!

I did use a new Hyundai TB. That's what is in there now. I didn't think about the reusing of the snap ring. DXD said I can ship everything back and they will repair or replace the parts that failed so we'll see. Once I get it back and if it fails again I may go with your conversion kit. How much is it? And can you use any non-turbo DSM Hi Po Clutch? What needs to be done to the flywheel? I'm running a Fidanza race wheel right now.

 

yup you can use any non turbo dsm clutch kit
act makes a good that i've useda few times with good luck
holds about 425 lb/ft of torque iirc
no modification needed,just slap in the conversiion kit and you're done
if you want to use the dsm turbo clutch kit you'll need to redo the bolt patern and the dowel pins on the flywheel

 

Ok, got off the phone with the South Bend clutch tech. They are going to fix my pressure plate for free. He said he's been working closely with Hyundai to figure out the problem. It appears that the problem is related to worn out clutch fork bushings and a worn carrier housing. There's two rubber bushings that support the clutch fork and the carrier is located on the transmission and goes around the input shaft. He said once these get worn the throwout bearing begins to whobble which then causes it to slip out of the pressure plate. For those with persistent clutch issues, JonGTR, I would check the condition of the bushings and carrier housing. Both mine were worn fairly badly.