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Posted by: BCinSC Jul 19 2003, 08:13 PM

As feared, the clutch failed due to oil soaking. It appears the rear main seal is leaking - when I touch with finger, oil spooges out. While I'm in there, what else should be replaced? I have the 20 piece kit from Pelican, the link to which I'll add in update post, and obviously, I need at least rear main seal and new flywheel to go along with new clutch disc and pressure plate. With a original CA 1.7L that had a whopping 69HP new (and maybe all of 60 now), should I bother with Pelican's lightened flywheel?

I noticed there's a passthru hole behind the flywheel into the engine compartment. It's about the size of the timing hole in the impeller housing (timing hole) and threaded, so I assume there's a cap. Is this correct and where do I get one? Is it same as impeller hole cap?

Can I clean tranny case completely while out of car? We hosed it down with brake cleaner and high-pressure washer before starting - 30 years of sludge buildup with a nice coat of oil on top neccesitated that. Of course, that got most off bottom, but top is NASTY. Now that it's out, what do I need to cover and protect? Should I clean and repack bearings in CV joints?

Of course, 5 out of 6 studs snapped off muffler due to excessive rust. The H.E. look in pretty bad shape. Figure I'll replace the whole shebang. Recommendations? Heat not required. Some 911 owners are going to Flowmeister mufflers; has anyone used similar on 914-4? Are Kerry Hunter's headers still the best? If not, could I have some stainless pipes fabricated?

Thank you,
Bruce Carney (and Dave McLaughlin aka DJM914-6)

Posted by: Lawrence914-6 Jul 19 2003, 08:33 PM

Can you post a picture of the hole you're referring to? I can't get an image of that in my mind.

Oh, when you powerwash the transmission, you can take an old spark plug and use it in place of the vent plug. That will help keep some water out.

Plan on replacing the input shaft seal and the two output shaft seals. Change your tranny oil and replace seals after you power wash, in case some water gets past the old seals.

Hope this helps,
Rusty

P.S. I R&R'd my tranny today, too. I forgot to put the cup bushing in when I had it apart last week.

P.P.S. Make sure you have new serrated washers for the CV joint bolts. Keep a few bolts handy in case you strip one or two.

Posted by: djm914-6 Jul 19 2003, 10:27 PM

What serrated washers for CV bolts? Funny, Dave and I both commented on wishing we had your number while pulling this apart. Took all afternoon. You gave it to me a couple weeks ago, but it's in my email in South Carolina and I'm at Dave's in Mass.

Posted by: djm914-6 Jul 19 2003, 10:42 PM

Realize now that I'm signed in as Dave. This is Bruce (BCinSC)

Posted by: djm914-6 Jul 20 2003, 10:44 AM

OK, some pics:

Hole behind flywheel into engine compartment


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Posted by: djm914-6 Jul 20 2003, 10:45 AM

Oil leak area


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Posted by: djm914-6 Jul 20 2003, 10:46 AM

Flywheel


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Posted by: djm914-6 Jul 20 2003, 10:47 AM

clutch disc


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Posted by: djm914-6 Jul 20 2003, 10:47 AM

other side


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Posted by: djm914-6 Jul 20 2003, 10:48 AM

Pressure plate


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Posted by: djm914-6 Jul 20 2003, 10:49 AM

again, in different light


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Posted by: ejm Jul 20 2003, 11:27 AM

The hole is a VW thing. On VW buses and Type 4's the hole is used to access the torque convertor bolts on the fully automatic transmissions. Even if they had produced a /4 sporto the hole would still have gone unused, sporto's and the VW auto-stick tranny's used a different set-up. I don't recall seeing one that was threaded but there was a cover that snapped in.

Bruce - Will you still be at Dave's next weekend?

Posted by: Aaron Cox Jul 20 2003, 11:56 AM

wierd- my 2.0 doesnt have that access hole. mine is a GA case- is yours?

Posted by: Lawrence914-6 Jul 20 2003, 12:08 PM

I don't ever remember seeing that hole. But I've only done clutch jobs on 2.0/4s.

Someone else is going to have to chime in... but you're right about replacing everything in there.

-Rusty

Posted by: djm914-6 Jul 20 2003, 12:27 PM

Yes, I (Bruce) will be here next weekend. This is an EB? engine (1973 1.7L California spec) all original (except fuel pump and steering wheel).

Posted by: cgnj Jul 20 2003, 12:47 PM

Hi,

I checked three cases in my garage. All of them have it. EC,GA,GC. Should be covered with a black plastic plug.

Carlos

Posted by: Brad Roberts Jul 20 2003, 12:53 PM

I see enough meat on that flywheel.. you should just have turned. Dont buy a new flywheel. We can help you locate a machine shop in your area that is familiar with a 2 step flywheel.

I also wouldnt worry about the lightened flywheel. The 1.7 needs all the rotating enertia it can get.


B

Posted by: Alfred Jul 20 2003, 01:02 PM

A lightened flywheel will have a lower moment of inertia.

Alfred

Posted by: Brad Roberts Jul 20 2003, 01:07 PM

Correct..

I feel that a 1.7 needs all the help it can get (heavy flywheel) a light one doesnt help you go over hills while running down the freeway.


B

Posted by: Lawrence914-6 Jul 20 2003, 03:13 PM

The black plastic plug. DOH!

I remember THAT.

Posted by: BCinSC Jul 21 2003, 11:05 AM

So, where do I get this black plastic plug? This board was inaccessible to me this morning, so I went ahead and ordered new flywheel from Darren at PP, along with rear main seal and front tranny seal. Any help locating a shop in either Burlington, MA area or Charleston, SC area? I'd go ahead and get it turned to keep as spare or offer up to someone who needed it.

Posted by: Brad Roberts Jul 21 2003, 11:12 AM

I wouldnt worry about the plug unless you absolutely feel you need one.

90% of the cars running around out there dont have them in place.

B