Finally fitted my 2.0L zetec to my Type 9 today - with just one problem. When fitting the clutch cover one of the location dowels was very slightly out of line (not pressed in quite straight). So I tapped it with a hammer to try to re align it and ... it broke off flush with the surface of the flywheel. Anyway with two dowels left and a clutch alignment tool I managed to get the clutch fitted and aligned perfectly. The question is : the dowels are there for location purposes only right ? The strength is from the six bolts holding the plate to the flywheel, so I can get away without the third dowel ?

I sure hope so because I don't fancy trying to drill the broken bit out.

From a previous thread its hells own job to get them out as their hardened. Im sure it will be OK, but no doubt conrod will put us right.

does he hole not go all the way through?,i would put a new one in even if it means getting an engineering firm to do it,slight out of line and it will vibrate like a nun on a friday night

Nope doesn't go all the way through and the clutch plate wasn't a "tight" fit on the dowels anyway hence the question about if they were only there to locate the cover whilst you are bolting it down. May be cheaper to get another 1.8 Zetec flywheel than to pay an engineering firm to remove the broken dowel

the dowels normally locate the cover where there is slack around the bolts,vauxhall use bolts with shoulders that are a tight fit in the cover so no need for dowels

thanks conrod, I think I am going to run with the broken dowel, whilst fitting it I couldn't see that the third dowel would make much difference other than making fitting the clutch assembly easier anyway.

If it does vibrate like a nun on a ... then I guess, I'll have to drop the box out and fix the problem (with a lesson learned). If it is OK then I'll fix it when the time comes for a new clutch or (more likely) I break the gearbox

As long as there is more than one intact dowel it should be ok
As long as you’re not going for high bhp.

If you need to get it out either drill a small hole from the other side and knock it out, or get a carbide drill bit and attempt to drill it out.

Just a word of warning the dowel(s) are not just for location they take most of the shear stress. If anyone ran a car without any dowels the bolts would more then likely shear off in very short order

do you consider 170bhp high bhp ?, if the dowels take most of then shear stress, I'm shocked at how easily one broke. I only tapped (and I mean tapped) it with a hammer to try and seat it properly.

contacted a clutch specialist this morning (this was playing on my mind). He assured me that the dowels are there for location purposes only and that one missing should not make any difference.

I know it is just another opinion, but all this company do is change clutches day in day out so on the balance of things I feel much happier now.

thanks for the advise everyone, just don't do what I did !!! if one of your dowels is slightly out of line PRESS it in properly in the vise or with a G clamp DON'T hit it with a hammer. Guess I live up to my username albeit not a big hammer on this occasion !!!



[Edited on 9/3/04 by givemethebighammer]

It sounds like the dowel you snapped was a bit dodgy.
10mm dowels should take a very hard whack before they brake.

In a tuning book I have it states that all flywheels should have at least one dowel, and any engines regularly running faster than 7500rpm should have 3 dowels in.

But like you say it’s just different peoples opinions, I think 2 dowels will be fine

On the balancing front could you glue the snapped peace of dowel into the hole, don’t know if this is a good idea but it might help.