After a recent clutch failure I have finally managed to remove all the various components necessary to get at the clutch and flywheel. My god, what a ball ache of a job! Feels like you have to disassemble the whole car!

When the bell housing first separated from the engine a dribble of clean coolant came out, and Inside the bell housing is a spattering of pink crystals, obviously there's been some leakage into that area. The car's not been using a particularly high amount of coolant, though has needed occasional top ups that I've attributed to the crazing in the header tank. I checked specific gravity of the coolant a few weeks back to check possible head gasket, and it was fine. A replacement header tank is waiting to be fitted.

So I have a few questions;
- where is that coolant in the bell housing likely to have come from?
- the flywheel is probably the most scuffed I've ever seen, and ideally I'd replace, but given their price new is it advisable to get it skimmed?
- the clutch release mechanism appears very stiff, I'm barely able to move it by hand. That's not normal is it?

Any advice greatly received.
Oh, suppose I better mention it's a late model 2004 1.8 petrol with about 80,000 miles on it.
Head gasket was replaced by a trusted mechanic at about 40k

Thanks in advance!

Trusted mechanic hopefully you received a service history of the work done.

Yeah and yeah. My Dad knows the guy personally and used to have him service all his cars for years. I've had the car over 3 years, but moved away soon after buying from him (bought it off the mechanic not my Dad!)

Burnham said:

I'd replace, but given their price new is it advisable to get it skimmed?

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It's best to replace the flywheel. Get a second hand replacement from a scrappy.

Burnham said:

the clutch release mechanism appears very stiff, I'm barely able to move it by hand. That's not normal is it?

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No. It needs freeing up before reassembly. Take the fork off and wiggle the shaft out the bush in the box. Then clean the shaft and grease with moly grease before refitting.

Burnham said:

where is that coolant in the bell housing likely to have come from?

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Lots of places. The coolant rail is right above the bell housing, so that could have a leaking hose. Also an amount of coolant can find it's way into the bell housing when the system is bled.

Burnham said:

Head gasket was replaced by a trusted mechanic at about 40k

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Hopefully he replaced the HG to LRs specification, or it'll fail again.

Thanks on all of that!

How would I check that a second hand flywheel wasn't warped?

He'd done a few K series HGs before, and it has lasted 40k so far... quite an achievement!

Cheers