Hi all,

So I recently acquired a 3.0L box and I'm planning to use it for a manual conversion to my TJS2.

When I bought it - the owner said it wasn't driveable because the clutch is slipping and boy was he right. We could barely get it moving and that was riding the clutch the whole way. Drove about 1-2kms and we gave up and ended up flat towing it home.

With so much damage to the clutch it has got me thinking that the flywheel may also be completely worn down so I may need a new one. When I rip apart the manual gearbox I will be able to see if the flywheel is irreparable but I'm not still certain that even if it can be machined - it will last for a good while so I'm considering changing my flywheel and (obviously) the necessary clutch.

Mitsubishi want around $800 for a new flywheel and through contacts I'm able to get a 230mm Exedy Clutch (std) for around $450. If I have too - I'll pony up the money but I've been reading around and seen some other options.
- I've seen talk of a 380 flywheel working with a 240mm clutch (found on alot of cars). Can anyone verify this? I can get the 380 flywheel for around $300 and the 240mm exedy clutch for $450 so $750 total.
- Otherwise I've read of even Evo clutches (much cheaper - around $300) fitting up in Magna's. Do these need the standard (expensive!) flywheel?

Also wouldn't mind some tips on what to look out for when doing the conversion. The donor car is a real basic exec TF 3.0L and my car is TJS2 exec (spec'd up to a Advance). I've got a good idea with alot of the How-to threads on here and around the internet and the many threads on this before. I know the difference ebtween the 3.5L & 3.0L boxes is ratio - but how does this affect you in real life.

I'd appreciate any help with this! Thanks heaps everyone!!

If the clutch plate design (riveted lining) is the same as a TS clutch, then you may find the flywheel in good condition. The clutch on my TS manual slipped real bad, but that was because the face on the pressure plate side was down to the rivets, causing the thing to slip. The lining on the flywheel side was not down to the rivets, so the flywheel was undamaged. Don't buy any parts until you open up the donor car and see what condition the bits are in. You might just need the standard clutch kit.

I'm using a 380 flywheel and exedy HD clutch in my 3.5 box, you could get the combo for a bit over 1k from Mal I expect. I am however having clutch slip issues with 255HP... But no one ever told me your supposed to bed a new clutch in so I've got nfi if this is the reason or not.

Evo 4-9 clutches and pressure plates will work too if you plan on making a little bit more power.

Always machine a flywheel too!

I would be very wary if you are being offered an "exedy" clutch for $450, this is well below cost price and with the amount of rubbish coming into Aust lately like fake Kuhmo Tyres etc, I would be very very careful

I would also state clearly not to use a baked flywheel, I have one in my workshop split in 3 where it was baked, machined and used again when the customer demanded it, it lasted 3 months until it fell apart as these do get cracks in them

If you want a used flywheel, I can do that, I can also supply the 380 kit with the 380 flywheel. Behind any std 3.5 will be fine, I have then running in 3.8's with 3.5 boxes as well as a host of other things as well.

Woob, also mate check your pedal toe play, when the car is hot, this could also lead up to the slip as the 380 kit has a heap of surface area and should handle your power with no worries at all

As for help on how to fit, really at the end of the day you will need to work this out mate or pay someone to do this who knows what they are doing and have your car ready that day and done properly.

Thanks for the replies everyone! :)


If the clutch plate design (riveted lining) is the same as a TS clutch, then you may find the flywheel in good condition. The clutch on my TS manual slipped real bad, but that was because the face on the pressure plate side was down to the rivets, causing the thing to slip. The lining on the flywheel side was not down to the rivets, so the flywheel was undamaged. Don't buy any parts until you open up the donor car and see what condition the bits are in. You might just need the standard clutch kit.

Well lets just hope this is the case. The flywheel's are so expensive so I'm hoping I will not need to buy one and get away with it being machined. I wanted to do a bit of research before as I do not have the luxury of spending time researching for parts after the box is out - I need to get this conversion done pretty quickly.


I'm using a 380 flywheel and exedy HD clutch in my 3.5 box, you could get the combo for a bit over 1k from Mal I expect. I am however having clutch slip issues with 255HP... But no one ever told me your supposed to bed a new clutch in so I've got nfi if this is the reason or not.

I'm going to be using a 3.0L box and I was looking at the HD clutchs but I wil not be chasing anymore power with this car. Its illegal for me on my P plates plus I think chasing more power in a magna is pretty futile. Not wanting to start an argument but yes I just need a clutch for everyday standard driving, The car may get the odd thrash here and there but I know how weak these transaxles are so I'm not going to abuse it too hard. So it seems you can use the standard 230mm clutch with the 380 flywheel? That would save me at least $500 as Mal has 380 flywheels for $300.


Evo 4-9 clutches and pressure plates will work too if you plan on making a little bit more power.

Always machine a flywheel too!

As above - not planning to chase much power but I'm aware that Evo clutches are a bit cheaper than the magna ones. Do these need to be mated to the standard (expensive) magna flywheels or can they be fitted to the 380 ones. Also do you need to modify the evo clutch at all or does it fit perfectly?

I would be very wary if you are being offered an "exedy" clutch for $450, this is well below cost price and with the amount of rubbish coming into Aust lately like fake Kuhmo Tyres etc, I would be very very careful

I've checked with this retailer and they guarantee that the clutch is from Exedy. They're a full certified exedy distributor and I was recommended by Exedy to contact them. They are very large and can order alot in at once and hence keep costs down. Thanks for the warning though.


I would also state clearly not to use a baked flywheel, I have one in my workshop split in 3 where it was baked, machined and used again when the customer demanded it, it lasted 3 months until it fell apart as these do get cracks in them

If you want a used flywheel, I can do that, I can also supply the 380 kit with the 380 flywheel. Behind any std 3.5 will be fine, I have then running in 3.8's with 3.5 boxes as well as a host of other things as well.

After seeing how bad the condition of the clutch was the other day, this is my fear. I'll have to see how bad it is when I take apart the donor car but I'm not so confident in this flywheel.

I'm considering using a second hand flywheel provided it is in decent condition. What is your price for one and is there some sort of guarantee that it won't crack apart in a few weeks? I do not mean to imply that you would sell a dodgy product but I am just hoping to have some sort of assurity that the flywheel will last a little while as taking these boxes out isn't easy and I wouldn't have the luxury of doing this every few months. Like I said I'm not planning on doing very hard shifts, launches and drops due to the transaxle's being quite weak, so I don't need something bulletproof - averaget to higher quality clutch would be fine. I would like the clutch & flywheel to last at least 120,000km's. In all honesty though - I don't think I willl keep this car for more than 2-3 years though.

Can the 380 flywheel & clutch work in a 3.0L box?

Appreciate the help Mal!

Just as an extra bit of info - I used an "Xtreme HD" 240mm clutch, and it has zero problems with a machined flywheel from Mal after 15000 k's.

A secondhand flywheel is just that, secondhand, I can look for any evedence of cracking and if I am satisfied then it can get sold. I can not guarentee without an exray of the condition of the internals of the casting

Interesting that a retailer is giving below trade prices, hope exedy do not find out lol.

Yes the 380 set up will work there is no difference externally between the 3.0 and 3.5 boxes, is only gearing

Just as an extra bit of info - I used an "Xtreme HD" 240mm clutch, and it has zero problems with a machined flywheel from Mal after 15000 k's.

I've heard of a few members as of late using this brand. Any reason you chose it over the exedy? And also what was the price? Thanks Pickles!

I've heard of a few members as of late using this brand. Any reason you chose it over the exedy? And also what was the price? Thanks Pickles!

The lone reason I chose it is because I got the kit cheap. $300 from someone on Ebay - I lucked out and the kit was in good nic. Theyre good clutches too, I havent driven a magna with an exedy in it but I cant imagine it not being too far different as the clutch application is linear throughout the pedal and it doesnt slip at all.

Cheers for that Pickles! Might call a few distributors and see what the price is for one of the Xtreme clutches. Worth a try.


A secondhand flywheel is just that, secondhand, I can look for any evedence of cracking and if I am satisfied then it can get sold. I can not guarentee without an exray of the condition of the internals of the casting

I understand that and it makes sense. Normal course of busienss for 2nd hand parts really.No guarantee of quality but of course it wouldn't be broken and damaged.


Yes the 380 set up will work there is no difference externally between the 3.0 and 3.5 boxes, is only gearing

No problems. Thanks for clarifying that. How does the different gearing ratio's affect driving & performance? From memory the 3L boxes have lower ratio 1st & 2nd gears.

__

Well after taking the gearbox out and having a look at the flywheel I can happily confirm its fine! No damage whatsoever! I'll have it machined and she'll be right to go with a new clutch.

I've now been looking at getting a 240mm Evo clutch? Reading through previous threads it seems I will need to do some slight work to the bellhousing to make sure the clutch clears the housing. It seems some sanding/filing/grinding will do the trick. Any other pro's/con's for getting one?

So my list is:
- Exedy standard clutch 230mm
- Exedy HD clutch
- Xtreme HD 230mm
- Evo 240mm clutch

Which one would you pick? Like I said I won't be always driving it hard but wouldn't mind to give it a bit of a go when it comes to a good hill climb or maybe the odd take off here and there. I'm a fairly tame driver and I won't be doing high rpm clutch drops and burnouts but rather do enjoy giving the engine a bit a rev once in a while. Do I need a HD or Evo one?

Appreciate any and every help! Thanks!!

You also need to machine a step into the flywheel depending on the brand you use

Interesting that a retailer is giving below trade prices, hope exedy do not find out lol.

Even if Exedy found out there isn't anything they can do besides dropping them as a distributor which is something they wouldn't want to do given there order sizes,infact if they tried to force the retailer to raise there pricing on there product the ACCC would kick there ass's!

Well after taking the gearbox out and having a look at the flywheel I can happily confirm its fine! No damage whatsoever! I'll have it machined and she'll be right to go with a new clutch.
So my list is:
- Exedy standard clutch 230mm
- Exedy HD clutch
- Xtreme HD 230mm
- Evo 240mm clutch
Which one would you pick?


Told you so re the condition of the flywheel. lol
Standard clutch will do, some slip will protect the gearbox when you decide to flog the car hard.

Glad to hear the flywheel is in good condition. The standard ones look pretty hardy.

I've been running a 380 exedy heavy duty clutch (the 240mm one) with my 3.0 litre gearbox and original flywheel. I had to have an extra step machined in to the flywheel but boy of boy it's so nice compared to a standard 225mm clutch that the car came with.

So easy to drive and grips so nicely when you want to drive it hard.

Get your flywheel machined after you get the clutch. I took the clutch to the machine shop as well so they could make sure it was going to fit when they were machining it.

As seen here (http://www.joshuaburford.com/clutch%20change/IMG_20101002_115608.jpg)

Thanks for the help folks!


You also need to machine a step into the flywheel depending on the brand you use

Good to know. Thank you. I'm having the flywheel machined anyway so I'll ask them to do this as well (if applicable). Do you know which clutches/brands need to have this done to the flywheel?


Told you so re the condition of the flywheel. lol
Standard clutch will do, some slip will protect the gearbox when you decide to flog the car hard.

lol Alright you win this time :P I was just concerned that the clutch bolts could've worn into the flywheel. The clutch was incredibly worn (about 2mm of meat left) but it was just above the bolts about 1mm which was lucky.

I might just go ahead and get the exedy standard clutch. This car is far from a racecar so I'm not going to drive it like one. Of course, I'm not doing the manual conversion just to build muscles in my left arm so I am wanting to put down a bit more power and have a little bit of fun with the car once in a while. Seems like the standard clutch is up to the job then.


Glad to hear the flywheel is in good condition. The standard ones look pretty hardy.

I've been running a 380 exedy heavy duty clutch (the 240mm one) with my 3.0 litre gearbox and original flywheel. I had to have an extra step machined in to the flywheel but boy of boy it's so nice compared to a standard 225mm clutch that the car came with.

So easy to drive and grips so nicely when you want to drive it hard.

Get your flywheel machined after you get the clutch. I took the clutch to the machine shop as well so they could make sure it was going to fit when they were machining it.

As seen here (http://www.joshuaburford.com/clutch%20change/IMG_20101002_115608.jpg)

Cheers for the recommendation Neo. :) I was planning to get the 235mm 3.5L exedy clutch. What would be the advantages of getitng the 240mm? I do drive in traffic a fair bit and being in the inner suburbs means plenty of stop/start driving. I wouldn't want to get something too heavy that would be uncomfortable to drive and make me tired having to push a heavy & hard clutch all the time.

I can't seem to find a 380 HD clutch (no "sports tuff" option on the exedy website) so how did you get yours?

Thanks for the help folks!



Good to know. Thank you. I'm having the flywheel machined anyway so I'll ask them to do this as well (if applicable). Do you know which clutches/brands need to have this done to the flywheel?



lol Alright you win this time :P I was just concerned that the clutch bolts could've worn into the flywheel. The clutch was incredibly worn (about 2mm of meat left) but it was just above the bolts about 1mm which was lucky.

I might just go ahead and get the exedy standard clutch. This car is far from a racecar so I'm not going to drive it like one. Of course, I'm not doing the manual conversion just to build muscles in my left arm so I am wanting to put down a bit more power and have a little bit of fun with the car once in a while. Seems like the standard clutch is up to the job then.



Cheers for the recommendation Neo. :) I was planning to get the 235mm 3.5L exedy clutch. What would be the advantages of getitng the 240mm? I do drive in traffic a fair bit and being in the inner suburbs means plenty of stop/start driving. I wouldn't want to get something too heavy that would be uncomfortable to drive and make me tired having to push a heavy & hard clutch all the time.

I can't seem to find a 380 HD clutch (no "sports tuff" option on the exedy website) so how did you get yours?

Mal/Madmagna got me mine.

I thought the sizes were the following: 225mm (3litre magna), 230mm (3.5litre magna), 240mm (380/vr4)

I drive in a fair bit of traffic when I have to as well and it doesn't feel heavy at all. It feels slightly heavier than the old standard 225mm clutch, but after converting my engine from 3.0 to 3.5 that old clutch went downhill fast. So I went the extra hill to make sure I don't have to change my clutch in a long time :)

Just to add - my 240mm xtreme HD doesnt need the flywheel to have a step machined in.

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