F28 onto 1.7 TD isuzu

[Jon_nova1]

OK, so i picked up a shell ready to take an F28 and let, the majority of the car is now together, I was going to V6 it but unfortunately have a 50 mile round trip to work daily so we came up with the idea of putting a 1.7TD engine into it

I have the F28 gearbox and the 1.7 isuzu engine out of an Astra MK2, We can get the gearbox onto the engine but if the F28 flywheel and clutch kit is used you can't disengage the clutch because the original diesel flywheel is around 15MM deeper where the friction plate contacts it

If the diesel flywheel and clutch kit is used there arn't enough splines on the friction plate for the F28 and the F28 friction plate is around 20MM wider than the diesel

The only solution i can think of is to find a friction plate that has the same splines as the F28 but the same width as the diesel contact plate, an F23 clutch plate has been suggested?

can anyone shed any ideas on this?:wtf:

Dodgy energy saving keyboard means i left the F out in the title:roll:

[mowgli]

have a looky in the online catalogue thread on my sig. there is a clutch catalogue on there.

can't you get the bigger flywheel/clutch from the xe/let to simply fit to the td engine?

you could get the td flywheel redrilled to take the f28 clutch, a decent engineer would do it easily

[Jon_nova1]

yes, i got the holes drilled on the xe/let flywheel but the contact area is about 15-20MM closer to the engine meaning the friction plate and clutch cover will sit the same distance from the engine which means by the time the clutch arm and thrust bearing have moved enough to touch the clutch cover the bearings fallen off the shaft.

Im not sure if i could get that extent of work done to the flywheel, the TD one is 4KG heavier so a hell of alot would have to be machined off, the TD flywheel is also smaller so by the time it comes to redrilling the holes for the clutch cover plate they will most likely be too close to the edge of the flywheel:confused:
Just looking at the F28 its got 14 splines (i thought it was 24) and the friction surface on the TD is 200~205, i don't have the clutch plates here so assuming it is 205MM i'll have loads of choicelol

[mowgli]

isn't the 4x4 flywheel massive? and the f20 type thinner??

[davidfox280585]

dervy has machined his flywheel to accept the xe clutch thus meaning you can run with no issues will find you his build thread

[davidfox280585]

page 17
http://www.pngclub.com/forum/showthread.php?146756-astra-boosted-derv/page17

[Nobby]

why do u want a f28 just use a f20 if you running a xe flywheel

[Dervy]

if you want better fuel economy, you will need an f20 from a astra gsi so you get the 3.45 final drive and then you will need to swap the f20 5th gear for the 5th gear from a f18w, that will give you the longest 5th you can get, its longer then the 6th gear in a f28.

[mk1nova_rich]

why do u want a f28 just use a f20 if you running a xe flywheel

He already has an F28 and an F28 ready shell...

[Jon_nova1]

wow, i really didn't think it would be possible to machine the diesel flywheel that much, how much did it cost you to machine the flywheel Dervy?? if its cheaper than a clutch friction plate to suit then i'll get that done

And because its either fit an F28 i already have, or sell the F28, convert the gearbox mount back to normal and go out and buy myself an F20.

Yep already read about the final drive ratio thing, to be honest i'd be happy if i get better fuel than the 1.9TDI golf im using atm

[Jon_nova1]

checked loads of clutches out, no one can seem to find what i need so have today had the flywheel lathed, i thought it would be a total nightmare but turns out you can put the clutch cover plate over it and it slots into the gaps of the deisel and the centres for the bolt holes on the F28 clutch cover can be easily marked

[Dervy]

have you looked at my pics of my flywheel

http://www.pngclub.com/forum/showthread.php?146756-astra-boosted-derv/page17

[Jon_nova1]

Yes i saw that which made me realise it is possible, although where your clutch cover plate bolts on its alot more shallower than mine, we must have different cover plates as i know if i did the same the bolts wouldn't even go into the flywheel lol

[Dervy]

yea i had to drill and tap new holes for mine. i did mine like this so in the future if i want i can run a bigger clutch like an xe one, which are 220mm, all i have to do is machine the middle out more.