HI Folks, I am writing from Calgary AB having some major issues with my '04 G35 Coupe which I have owned for past 2 years and need your help. Sorry this is a long one:

Background:
My ordeal started about 6 weeks ago when the clutch started slipping, followed by difficulty engaging into 1st and 2nd, along with an intermittant heavy whirring/grinding noise. The mechanic I had my vehicle dropped off at advised that the Clutch needed replacing along with the FlyWheel. Net cost $2,400 materials, plus 5 hrs labour, totalling about $3,000. Thinking this was a bit excessive, I ordered online through Vivid Racing a ClutchMasters FX200 and AL flywheel. Product arrived about 1 week later and mechanic proceeded to install. This is when the problems started.

Problem #1 - Clutch Won't Fit
The mechanic vehemently claims that the clutch is the wrong size. Basically when up in the air on the rack, they can engage/disengage the clutch. Once its lowered and on the ground, the clutch just will not engage/disengage. He tried replacing the slave cylinder but that was not at issue. The claim is that the fingers are not out far enough to grab the thrust bearing. Recommendation - Buy his original clutch (Beck Arnley) and resurface fly wheel. I've been in touch with Clutch Masters, and had technical support directly talk with mechanic but we still can't get it to work. Not having a lot of other choices I went and authorized his recommendation. Another week passed and I got call to say car is good to go. Total bill $2700 (labour, Beck Arnley Clutch, Resurface Fly Wheel, Crank Sensor). Yes apparently he broke the original crank sensor and I had to pay for a new one. I was also told that the A/C Compressor makes "some noise" and I should save $1200 up to pay for that…soon.

Car Fixed - Not so much
I picked up the car later on that evening when shop was closed. Problems as follows:

• Car now takes multiple cranks (like turn the ignition for good minute, its hit and miss)
• Grinding/Whirring Noise is still there and its HORRIBLE. I immediately recognized that this was the sound being made when I dropped off 5 weeks ago.
• SLIP, VDC, SEL lights all on
• Clutch is quite soft, I find it very hard to distinguish engagement/disengagement
• Moving into reverse, I hear a "ping-ping-ping" when I move the shifter and press down. Once engaged everything is fine. Its just when pressing down I am unsure what that noise is…other than it did not make the noise at all before.

I expressed my dissatisfaction next day. Authorized the A/C Unit replacing and advised that I want my car back with expectation better than the shape I took it in with.

Final Bill
So I am going on 6 weeks now and into this repair for $1200 + $2700 + $1200 = $5,100. I am hopeful that Clutch Masters / Vivid Racing will take some pity on me and refund partially for return (otherwise i have a clutch and flywheel for sale or very expensive paper weight). I have not got the final bill yet, so who knows actually where this ends or when (groan).

Questions
1. Can anyone comment on how an OEM clutch replacement should "feel" ? Maybe someone who has had a G35 since new? My old clutch prior to this felt pretty stiff and I had a good few inches of play to engage/disengage. I notice that movement got longer as the clutch started to ware. The new OEM replacement clutch has IMHO very little in the way of movement between engaged/disengaged….to the point were I stalled it immediately after taking for "test drive" (driving for almost 18yrs with manuals). I found that you have to ride the clutch a fair bit at low speed to prevent. What worries me is whether this is the same issue related to the FX200 clutch??

2. Any thoughts on why the start issue is all of a sudden coming up? Mechanic tried replacing the crank sensor (again) but that was not issue. Is this just because G35 has been sitting disconnected for 5 weeks?

3. Anyone had similar issues with mechanic indicating clutch will "not fit"?

Any anecdotal comments are welcome, and apologies if I have not posted this in right place. I'll keep this post updated as I move forward and hopefully help someone else avoid this mess.

 

When mine went bad, I ordered a Jim Wolf Technology clutch pack (comes with EVERYTHING) for less than 800 dollars and my mechanic charged me 400 dollars to install it. It is good for 450 hp and the only problems are a rattle from the lightweight flywheel (normal) and the increase in muscle mass in my left leg (harder to work, but not at all bad). I think you got hosed.

 

Car now back things appear to be back to normal. It turns out that the shop had not carefully noted the small dimple on the crankshaft. This caused the crank sensor to not pickup position properly, not allowing for a proper start. Once this was fixed car back to starting everytime. The ping-ping-ing in reverse has disapeared, all grinding noises gone away. Sadly this took a lot of $$ to fix. Now I just have to try and return the FX200 flywheel and clutch. Fingers crossed.