Clutch Replacement on Manual 4WD Bongo

[PeriRollah]

Hi all..

I am in the process of looking to change the clutch in my manual 4wd bongo after hearing so unnerving rattling sounds when the bongo is in neutral idling. It is sounding very much like clutch release bearing rattle/ failure. The car still engages in gear and can drive. And the noise disappears once the clutch is depressed.


According to the part numbers from the worskhop diagrams for the clutch I am seeing:

the part number for the

release bearing G56116510
clutch plate WL0216460
clutch plate cover: WL0116410 / WL0216410

I have seen a kit which details:

but the part number for the clutch plate is WLA2-16-460F S2 and not WL0216460

A long shot, but has anyone had to change a clutch on their rare manual bongo or know the significance of the WL02 and WLA2 part numbers please?

I am also getting a violent vibration above 10 mph but those symptoms sound more like drive or propshaft but assuming related as both rattling and vibration issues started at the same time.

Any help hints pointers would be greatly appreciated (I am awaiting a call back from BongoSpares re a clutch kit ) but thought I would ask on here in case anyone has had to replace their clutch.

Thanks Dek

[Doone]

Sorry I can't help with your question. A search on the forum found this post, which has information that might be useful:
https://igmaynard.co.uk/bongo/forum/vie ... al#p716835
And this, which mentions an ADL manual clutch:
https://igmaynard.co.uk/bongo/forum/vie ... hp?t=49961
NorthernBongolow may be able to advise: https://igmaynard.co.uk/bongo/forum/mem ... ile&u=7597

[PeriRollah]

Thanks Doone,

Much appreciated, especially that post re vibration.

The first comment on that post about larger clutch plates is apparent when you search for clutch replacements for bongo. seems to vary with stated size

I am going for a Borg & Beck replacement so will keep fingers crossed and report back

Thanks Dek

[Northern Bongolow]

That's what I put in mine without any problem...
I did have to do the master innards and a replacement slave cylinder.

[PeriRollah]

Thanks for your reply,

Can you remember what borg and Beck part number you used? My garage seems to think it is a HK2545 ; but that states for use with dual mass engines.

I thought it should be a HK2094

The conflicting information makes me unsure :-/

Going by the mazda prt number for a up 1997: https://www.autodoc.co.uk/car-parts/oem/wl0216460

The ADL Blueprint part number for just the disk is ADM53149 for:

Manufacturer/Model/Type/KW/Manuf. year (from - to)

MAZDA
MAZDA MPV I (LV) ( 05.1996 - 09.1999 , 115 PS)
MAZDA E-Series III MPV (SG) ( 06.1995 - 09.1999 , 125 PS)

But I cant find that in a kit with the cover and bearing

[PeriRollah]

So I managed to speak to Holly at Mazdabongo.com is so super super helpful and

ADL blueprint number for the kit is ADM53073 .
Cross references to Borg + Beck HK2094

With my VIN and liaising with Mazda themselves they were able to find the correct kit

I will see what happens when the gearbox is taken apart next week

[Doone]

Fingers crossed for you.

[PeriRollah]

Thanks Doone.

After some more diagnosis over a garage pit. There is a knock/noise every 5 or so seconds from the rear of the gearbox / transfer case when idling in neutral with clutch not pressed. Placing hand on both gearbox and transfer case, it's possible to feel the vibration of the knock. And then there is nothing untoward when clutch is pressed (in neutral)

However, when the bongo is rolling (Down a gentle slope) in gear, whether the clutch is pressed or not there is a point when the bongo wants to stop rolling say every 5 - 10 metres and the bongo will stop, unless there's enough momentum to take it past this particular point with a clunk/resistance, in the revolution of a gear or shaft perhaps .

This is the vibration I was experiencing going fwd in first or reverse slowly. . So I'm thinking maybe damaged tooth in gearbox or transfer case Now, as this resistance point /clunk is NOT happening when the gearbox is in neutral whilst coasting.

Hopefully it will become apparent when the gearbox is taken off.