 Now it's my clutch... |
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| RustyWa |
 Apr 13 2005, 11:44 PM
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#1
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Working Member  Group: Members Posts: 610 Joined: 2-January 03 From: Kent, WA Member No.: 72  |
My poor car is putting me to the test this week. I'm driving around today and start heading up this large hill in third gear, when it's obvious that my clutch is slipping. I've adjusted the cable out before and essentially if my foot even gets close to the clutch pedal, the clutch slips. In fact I have to be mindful of my shoe laces since the weight of them seems to cause slippage.
I'm going to look at it once more tomorrow, but I think I'll have to bite the bullet and pull the tranny. And to think I was getting all gung ho upgrade my control arm & trailing arm bushings. Looking at the Pelican site, they have a "Super Kit" for the low, low price of $387.75. Which includes the following: New Pressure Plate New 911 Clutch Disc New Throw-out Bearing New Pilot Bearing and Felt Ring 2 Throw-out Bearing Guide Clips New Throw-out Fork Bushing 2 CV Joint Gaskets 2 Muffler Gaskets New Flywheel O-Ring New Flywheel Bolts New Flywheel Metal Crush Gasket Clutch Disc Alignment Tool Flywheel/crankshaft seal not included - check yours first before ordering. Is this overkill? Anything else needed? |
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| dinomium |
Apr 13 2005, 11:53 PM
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#2
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Git on a chair son, all the good stuff is goin over yer head! Group: Benefactors Posts: 2,777 Joined: 2-January 03 From: Bremerton, WA Member No.: 74 Region Association: Pacific Northwest  |
while yer inthere... how is your clutch cable? Pay really close attention when unpacking the kit form PP, I didnt and missed the felt washer. (IMG:http://www.914world.com/bbs2/html/emoticons/ohmy.gif)
The cats a Pelican got me another, but I felt pretty lame. |
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| Bleyseng |
Apr 14 2005, 07:56 AM
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#3
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Aircooled Baby! Group: Members Posts: 13,035 Joined: 27-December 02 From: Seattle, Washington (for now) Member No.: 24 Region Association: Pacific Northwest |
Not a bad deal, but get the new rear main seal and install it since you are taking off the flywheel.
Geoff |
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| tat2dphreak |
Apr 14 2005, 10:20 AM
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#4
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stoya, stoya, stoya Group: Benefactors Posts: 8,797 Joined: 6-June 03 From: Wylie, TX Member No.: 792 Region Association: Southwest Region |
(IMG:http://www.914world.com/bbs2/html/emoticons/agree.gif) I didn't know what the little plastic thimble looking thing was I realized after I already got it back together (IMG:http://www.914world.com/bbs2/html/emoticons/dry.gif) luckily the one that was on there was in good shape... and I didn't throw the new one away... I did it a little different though... I got a 6 spring clutch off ebay(new sachs clutch), and bought everything ELSE in the kit from pelican, and spent about $60 less... I had the flywheel done locally by a reputable VW machince place Wes recommended... they did the wheel for about $30 in less than an hour |
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| RustyWa |
Apr 14 2005, 10:26 AM
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#5
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Working Member Group: Members Posts: 610 Joined: 2-January 03 From: Kent, WA Member No.: 72 |
So is having the flywheel turned a must then? I was just checking out ebay...makes me a little nervous.
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| tat2dphreak |
Apr 14 2005, 10:32 AM
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#6
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stoya, stoya, stoya Group: Benefactors Posts: 8,797 Joined: 6-June 03 From: Wylie, TX Member No.: 792 Region Association: Southwest Region |
I personally believe it is... if you see blue on the fly wheel, it needs turning IMO... and mine had blue all over in places... |
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| Eric Taylor |
Apr 14 2005, 12:46 PM
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#7
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Senior Member Group: Members Posts: 909 Joined: 1-June 03 From: Newport, OR/Eugene Oregon- UO Member No.: 770 |
From my experience with the pelican kit it was worth it. They include all the stuff you need and a lot you never would have thought off. It makes it really nice to know the clutch was done right. As far turning the flywheel, I would take it off and take it to a machine shop and ask them what they think. Some times it is really obvious, and some times it's not. Usually they have wear groves from the old disc and do need to be turned or the new disc will slip, but it's hard to say without looking at it. Have fun taking the flywheel bolts off (IMG:http://www.914world.com/bbs2/html/emoticons/smile.gif)
Eric. |
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| tat2dphreak |
Apr 14 2005, 01:00 PM
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#8
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stoya, stoya, stoya Group: Benefactors Posts: 8,797 Joined: 6-June 03 From: Wylie, TX Member No.: 792 Region Association: Southwest Region |
the flywheel bolts AREN't THAT bad... just use a 2' break over bar and the are nothing! (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif) |
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| Eric Taylor |
Apr 14 2005, 04:39 PM
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#9
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Senior Member Group: Members Posts: 909 Joined: 1-June 03 From: Newport, OR/Eugene Oregon- UO Member No.: 770 |
yeah, that's the way it went for me, but only AFTER I nearly broke my arm off!
Eric |
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| dinomium |
Apr 14 2005, 04:48 PM
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#10
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Git on a chair son, all the good stuff is goin over yer head! Group: Benefactors Posts: 2,777 Joined: 2-January 03 From: Bremerton, WA Member No.: 74 Region Association: Pacific Northwest |
flywheel locking thingy?? I just use an air wrech...
bhhhhhhhhhhhhrip we need an air gun smilely |
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| Bleyseng |
Apr 14 2005, 05:05 PM
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#11
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Aircooled Baby! Group: Members Posts: 13,035 Joined: 27-December 02 From: Seattle, Washington (for now) Member No.: 24 Region Association: Pacific Northwest |
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| RustyWa |
Apr 14 2005, 10:47 PM
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#12
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Working Member Group: Members Posts: 610 Joined: 2-January 03 From: Kent, WA Member No.: 72 |
I was just wondering if an impact gun would be ok. I guess it is...excellent.
I adjusted the clutch out this afternoon, about 3-4 turns, and it still slips in 3rd gear, even on flat roads. I'm going to adjust it out some more just to make sure I didn't have it to tight. Otherwise, the tranny is coming out this weekend so I can see what I've got. What's this end play junk I've been reading about? Should I check this before I remove the flywheel? I've got the correct dial indicator and mount to do this, I'm just confused at when to do it and how much needs to be installed. |
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| SpecialK |
Apr 14 2005, 11:04 PM
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#13
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aircraft surgeon Group: Benefactors Posts: 3,211 Joined: 15-March 04 From: Pacific, MO Member No.: 1,797 |
Okay, this might sound stupid [might...hell].
If your clutch is "sensitive" to the slightest clutch pedal pressure, wouldn't that indicate that your T/O bearing is already making some pretty good contact with the pressure plate, and you need to adjust it the other direction? |
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| RustyWa |
Apr 14 2005, 11:27 PM
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#14
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Working Member Group: Members Posts: 610 Joined: 2-January 03 From: Kent, WA Member No.: 72 |
Now I am slightly confused. Loosening the cable at the tranny should cause the T.O. bearing to move away from the pressure plate correct? My goal is to loosen up the cable to make sure I didn't have it adjusted to tightly which was causing the "sensitive" pedal. |
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| sixnotfour |
Apr 14 2005, 11:57 PM
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#15
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914 Wizard Group: Members Posts: 10,433 Joined: 12-September 04 From: Life Elevated..planet UT. Member No.: 2,744 Region Association: Rocky Mountains 
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You're , On the right track,
If that works ,but then you cant get in gear ,grind. It may be the clutch cable tube has pulled loose. Any luck you wont be doing the clutch job. |
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| RustyWa |
Apr 16 2005, 04:03 PM
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#16
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Working Member Group: Members Posts: 610 Joined: 2-January 03 From: Kent, WA Member No.: 72 |
Well, got the tranny and clutch assembly removed from the car this morning. Not a bad job. I did have one little episode. The tranny wasn't balanced quite right on my floor jack and 2x4's and slid off hitting the concrete. I can't find any cracks anywhere, so hopefully everything will be fine.
The clutch, T.O. bearing & pressure plate are toast. The clutch disk was down to the rivets on the pressure plate side and was starting to dig into the flywheel bolts on the other side. The pressure plate has grooves on it's face and the fingers. The T.O. bearing also has some major grooves in it. The flywheel intrigues me slightly. There is some grooves in it's face, but also what looks like machining marks. Since everyone likes photos, here you go... T.O. bearing. (forgot to turn macro on) Attached image(s) 
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| RustyWa |
Apr 16 2005, 04:04 PM
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#17
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Working Member Group: Members Posts: 610 Joined: 2-January 03 From: Kent, WA Member No.: 72 |
Flywheel bolts
Attached image(s) 
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| RustyWa |
Apr 16 2005, 04:04 PM
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#18
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Working Member Group: Members Posts: 610 Joined: 2-January 03 From: Kent, WA Member No.: 72 |
Attached image(s) 
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| RustyWa |
Apr 16 2005, 04:05 PM
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#19
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Working Member Group: Members Posts: 610 Joined: 2-January 03 From: Kent, WA Member No.: 72 |
Pressure plate where flywheel bolts started rubbing.
Attached image(s) 
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| RustyWa |
Apr 16 2005, 04:09 PM
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#20
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Working Member Group: Members Posts: 610 Joined: 2-January 03 From: Kent, WA Member No.: 72 |
Finally a close up of the grooves in the flywheel. Plus you can see the machining marks. Why would the clutch/flywheel wear so unevenly?? It didn't appear that it was into the rivets on this side, but they weren't far off.
If I get this resurfaced, is there anything special I need to do when I reinstall it? Attached image(s) 
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