02 clutch replacement issues

[infamous amos]

I am in the process of replacing the clutch on my 2002 Lincoln LS V6 with a manual transmission. I began my clutch replacement project with the EXEDY KLN01 OEM Replacement Clutch Kit. Upon visual inspection, the components appear nearly identical. However, when I went to install the new pressure plate I found that the pressure plate and flywheel did not mate completely flush. The replacement pressure plate is slightly different than the original as photographed below:

A representative from Exedy has told me "[are you] reusing the OEM used dual mass flywheel? This is required to be replaced whenever doing a clutch job on this vehicle, it is a non re-usable part. The new OEM flywheel may be a revised version which fits this clutch kit."

Now, my question is; where should I purchase the flywheel? Will any replacement flywheel work with this Exedy clutch kit? Has anybody already done a clutch replacement on their LS? I am probably going to take the new clutch kit to the dealer today to see what they say. I guess this is what I get for trying to save a few bucks.

Any insight is greatly appreciated.

 

[Mechanicboy]

However, when I went to install the new pressure plate I found that the pressure plate and flywheel did not mate completely flush.

A representative from Exedy has told me "[are you] reusing the OEM used dual mass flywheel? This is required to be replaced whenever doing a clutch job on this vehicle, it is a non re-usable part. The new OEM flywheel may be a revised version which fits this clutch kit."

Now, my question is; where should I purchase the flywheel? Will any replacement flywheel work with this Exedy clutch kit? Has anybody already done a clutch replacement on their LS? I am probably going to take the new clutch kit to the dealer today to see what they say. I guess this is what I get for trying to save a few bucks.

Any insight is greatly appreciated.

I can't help you much at the moment but I do need clearification of what mean by not flush. If you mean the pressure plate is hitting the clutch disk not allowing the bolt mounting area to sit flat against the flywheel than this is normal. As for buying a new flywheel good luck. I'll try to help you this weekend but I ended up buying one from england for a jaguar s-type because it's the LS' sister car and uses the same flywheel.

 

[infamous amos]

The three metal..... nubs?... protrude much further on the new pressure plate than the original which does now allow the pressure plate housing to mate flush with the clutch disc housing.

Did you purchase your clutch and flywheel at the same time? This is one of the few websites I have found a flywheel for my car: http://bit.ly/m53spg

I'm just worried that if I drop the ~$640 for this flywheel that it still won't fit and I will be dealing with returns to two online retailers.

Thanks for your help!

 

[Kumba]

I am probably going to take the new clutch kit to the dealer today to see what they say. I guess this is what I get for trying to save a few bucks.

Any insight is greatly appreciated.

The dealer will say "Yeah, don't know what is wrong. If you pay us to put a clutch in it we will fix it! Durhhhhhh". At least that has almost always been my experience. Unless you want to stand around and try to talk to one of the tech's, good luck getting an answer. I've actually had better luck just walking through/around the shop in the back acting like you own the place and talking to the guys. The service managers are all about the money, and rightly so to a point.

Off hand, I would say you need a different flywheel for aftermarket, or that's not the right clutch. What I don't see pictures of are the friction disk or flywheel so I can't really guess how it should go together. I would think it odd that those pins are taller then the friction disk without reason.

My second thought is that those nubs are alignment pins that match up with the flywheel. If that's true, there is probably a certain way that it has to be put on to match. If you are rotated one hole off, it might not fit.

Can you post pics of the flywheel too so we can see what we are working with?

I've never used Exedy before, but I have used Sachs in the past who offers a kit for your car. It was pretty much a direct fit on my F150 with IL6. Not sure how the applies here but ohh well

 

[milehighmikey]

I've never used Exedy before, but I have used Sachs in the past who offers a kit for your car. It was pretty much a direct fit on my F150 with IL6. Not sure how the applies here but ohh well

I got mine through rockauto, with sachs components, clean, perfect fit on my 2000.

 

[infamous amos]

My second thought is that those nubs are alignment pins that match up with the flywheel. If that's true, there is probably a certain way that it has to be put on to match. If you are rotated one hole off, it might not fit.

I believe these are alignment pins, however, they are in a different location than the stock and their height is what is causing the gap between the pressure plate and flywheel.

I got mine through rockauto, with sachs components, clean, perfect fit on my 2000.

There are two kits on rockauto; the exedy and the sachs. Neither kit comes with a flywheel, and there is not a separate flywheel available on the site. Did you replace your flywheel when you replaced your clutch? The jabroni at Exedy told me that the flywheel should be replaced when doing a clutch replacement on our cars.

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Thanks guys for the responses. I think I'm going to take the Exedy clutch in to my local dealer to ask them why it doesn't fit.

 

[Mechanicboy]

I bought my clutch kit and flywheel from different places. I paid FAR less than $640 for my flywheel and that was with shipping from England. I almost bought a spare and regret not doing so.

If I remember to look tomorrow I still have all my old parts and can see if mine is different than yours. I remember all my stuff was stamped "luk"which was the brand and was identical to what I took out.