TOB damaged my bell housing

[BrokenTsi]

I just installed my brand new Jacks transmission the other night. I just got it back from another rebuild due to stripping out 3rd gear and twisting the splines on the evo 3 input shaft.

I filled the trans with fluid, and proceeded to bleed the clutch. I had a buddy push on the clutch pedal, and I heard a popping noise. OK, looked around, didn't notice anything, clutch fork is moving and has great range. The fork sits where it needs to for proper adjustment. The only thing I changed on my setup was my clutch discs. I upgraded from the original QM discs to the V-drive. I re-used the flywheel, pressure plate, clutch fork, TOB, as they all only had 5k miles on it.

My clutch felt aweful. I never drove the car because I could not get the clutch to disengage. I did manage to get it in 1st gear while on jackstands, but the clutch was dragging bad.


After more diagnosing, I pulled the trans to find this..........

I have no clue what happened. The end of the TOB post is mushroomed a bit, but the rest of fine. Think I can just file it down, smooth it, and run it? Or am I looking at a bell housing swap? The TOB appeared to have melted, which is weird, cause I only ran the car for less than 20 seconds while on jackstands.

 

[twicks69]

See my DSMLink post.

Tim Zimmer via Evo Phone

 

[stevenr816]

Holy shit thats awesome. No clue how that would happen.
File it down and maybe use some fine grit paper on the sliding surface. Make sure to lube up with some high temp grease after it's all done.

 

[BrokenTsi]

For those wondering what happened, it turns out its a design flaw of the new gear drive discs. The hub of the clutch discs hit the post that the TOB rides on. I either need to machine the hubs, or get the correct discs from Quarter Master.

It looks like the bell housing can be repaired with a file and some sandpaper.