Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing Bad bellhousing "notch" in TR 4a powered +4

So while changing my badly worn, sloppy, clutch linkage, I found this:






A pretty impressive notch on the RIGHT side of the bellhousing slot for the clutch release...

I've heard that the motion of the spinning clutch can lead to a notch on the LEFT side of the bellhousing slot - I'm curious as to what caused this impressive notch?

I'm thinking of using the stainless metal plate repair fix described here: https://madaboutmorgans.com/reconditioning-the-4-clutch-release/ as a solution, but using it on the RIGHT side instead of on the LEFT (as described in the link above).

Questions:

1) Do you think the plate fix described in the link can be done with the bellhousing in the car? I think I could get a dremel in there to widen the slot to accept the plate, but I'm worried about the metal shavings left behind.

2) What causes the notch on the RIGHT side?

3) The clutch action feels fine to me, is there any reason to correct this - or should I just live with it?

As always, many thanks.

-GC

To do the job properly, it's a bell housing out job. You will also need to check the fit of the clutch release sleeve in the bellhousing. Usually they wear and become very loose in the housing which causes the notching as the sleeve flops about! Solution is to bore out the bell housing and fit a stainless liner in which the clutch operating sleeve slides. Check the alloy clutch release sleeve as well for cracks where the carbon release bearing fits.

Not a fan of the metal plate repair method. My method involves finding a needle roller bearing with a 1/2" ID to fit over the clutch sleeve peg and the set the bellhousing up on a mill and mill the slot to suit the OD of the needle roller bearing to allow the bearing to slide up and down the slot rather than the peg.

Arwyn

Thanks Arwyn...the needle bearing solution sounds very elegant...unfortunately I don't have a mill

Yep, Arwyn is totally on the money. It's got to come out! That is a pretty impressive damage pattern which looks like both sides have already been used by the wear patterns. Re machining and sleeving will be necessary after rebuilding the lost alloy. Billy Bellinger might be worth a call for repair or replacement or a gearbox specialist like Ashcroft. The stainless plate repair on one as damaged as yours would be a bodge job and I don't think it would be a suitable solution however I have often thought that stainless inserts fitted to a good bell housing would protect the opening when wear occurs allowing the moving parts to contact the housing.

OOP's see you are in the states, Try a TR club etc

Difficultly in having the slot welded back to reclaim it is that the bellhousing is made from Elektron which is a high magnesium alloy. Unfortunately, welders prepared to weld Elektron are few and far between. Not sure bell housings are available new as my Dad bought the last one from the factory circa 1986 for our 1968 Plus 4!

So I understand that Morgan Spares here in the US will supply both rebuilt ( Stainless Steel Sleeved) bellhousings, and will also sleeve an existing bellhousing.

My question for the group is...If the clutch is operating normally, does the bellhousing need to be fixed? I understand that it will continue to wear - but to my eyes, this bellhousing is pretty shot, I'd rather buy a new, better, rebuilt bellhousing in 5 years than spend the money on this one...

Thoughts?

Well after Arwyn's advice I think I would agree with your last decision but I might ask them to install the stainless rub plate as well. High magnesium alloy is really hard to weld and even a good tig welder would fail, It pops and splatters everywhere! and doesn't stick!
However you decide to do things, Arwyn is probably the best opinion you will find. Best of luck crowbar.

I got some new old stock if it got any interrest

+4competition, could you PM crowbar just in case he doesn't pick it up! Thanks, Martin.