Pressure plate wear., Causes. Options

[Steve]

Make sure you have a 1/2" free play at the pedal. I use a ruler or tape measure and pull and push the pedal by hand to measure it.

[GregAmy]

Another consideration is that the throwout bearing and pressure plate were somehow not co-axial. I'm sure you can imagine that kind of wear if one was slightly off and they were rotating on slightly-different centerlines.

I believe above you mentioned you're replacing the plastic fork bushings and pivot cup? Also check the condition of the tube that the TOB slides on, to ensure no excessive wear, and make sure it's centered. Probably want to replace the trans input shaft seal anyway...?

[TravisNeff]

There is also the shim behind the ball for the cup bushing on the throw out lever. When people resurface flywheels they may add more washers. I am not sure what thickness, if any washers are needed. Something to look at or think about before you put it back together.

[rgalla9146]

Shudder at take off ?
Possible bent throw-out fork or uneven wear where lugs of TOB fit into fork.
TOB also needs to rotate freely on axis of lugs
As mentioned incorrect clutch adjustment.....no free play

[Mark Henry]

Shudder at take off ?
Possible bent throw-out fork or uneven wear where lugs of TOB fit into fork.
TOB also needs to rotate freely on axis of lugs
As mentioned incorrect clutch adjustment.....no free play

(IMG:style_emoticons/default/agree.gif)
This is one you should check especially if you have a heavier than stock PP. I welded in some gussets on my shaft arms (forks) because I have a HD PP on my 3.0 /6 conversion.
HD RB shafts and/or welding up the forks are common in the type one trans crowd.

[wndsrfr]

Shudder at take off ?
Possible bent throw-out fork or uneven wear where lugs of TOB fit into fork.
TOB also needs to rotate freely on axis of lugs
As mentioned incorrect clutch adjustment.....no free play

(IMG:style_emoticons/default/agree.gif)
This is one you should check especially if you have a heavier than stock PP. I welded in some gussets on my shaft arms (forks) because I have a HD PP on my 3.0 /6 conversion.
HD RB shafts and/or welding up the forks are common in the type one trans crowd.

Mark...got a photo of the gusset weld-up??

[Mark Henry]

Shudder at take off ?
Possible bent throw-out fork or uneven wear where lugs of TOB fit into fork.
TOB also needs to rotate freely on axis of lugs
As mentioned incorrect clutch adjustment.....no free play

(IMG:style_emoticons/default/agree.gif)
This is one you should check especially if you have a heavier than stock PP. I welded in some gussets on my shaft arms (forks) because I have a HD PP on my 3.0 /6 conversion.
HD RB shafts and/or welding up the forks are common in the type one trans crowd.

Mark...got a photo of the gusset weld-up??

Sorry not of my cross shaft but this ebay ad shows the bugpack type 1. Mine looked similar once done.

https://www.ebay.com/itm/EMPI-BUGPACK-18-10...2-/264129462098

[Spoke]

What does the wear on the TO bearing look like? If the PP was wearing then the TO should show a similar profile.

[rgalla9146]

What does the wear on the TO bearing look like? If the PP was wearing then the TO should show a similar profile.

Usually it's not so much what it looks like but what it sounds like.
The typical failure of a TOB is noise that changes with pressure on/off the
pedal. This is caused by dried out lubrication wihin the bearing.
Less common but possible is the TOB sticking or resisting free motion in the fork.
Another issue is the TOB sticking on the guide tube......last but not least is
a worn out pilot bearing.

[914Toy]

What does the wear on the TO bearing look like? If the PP was wearing then the TO should show a similar profile.

Usually it's not so much what it looks like but what it sounds like.
The typical failure of a TOB is noise that changes with pressure on/off the
pedal. This is caused by dried out lubrication wihin the bearing.
Less common but possible is the TOB sticking or resisting free motion in the fork.
Another issue is the TOB sticking on the guide tube......last but not least is
a worn out pilot bearing.

The throw out bearing (TOB) looks perfected at first glance, and has a smooth no slop action and turns easily. There is some slight wear evidenced by a bur around the outside of the contact ring, and in certain light shining back to ones eye there are some very shallow "indenture scallops" on the contact ring surface. There were no typical TOB sounds before removing this TOB and no vibration or sound when spinning it in my hand. It is not dry, but possibly the grease was beginning to dry. The fork is in good shape and the plastic positioning shims/spacers are in good shape, and the plastic ball cup was new and looks perfect. The TOB tube looks OK as does the needle pilot bearing which still has grease.
Bottom line, the TOB appears close to good condition as does the guide tube, clutch fork, and spacers, and ball white plastic cup. But I will be installing a new TOB, along with a new pressure plate assembly.

[roblav1]

Looks typical of clutch cable too tight.

[914Toy]

Completed installing the tranny with new pressure plate (Sachs 228 mm) on the aftermarket flywheel - cleaned up with some fine emery paper - and a new throwout bearing. Adjusted the cable so that the clutch engages at about 1/3 to 1/2 distance out from floor board stop. Clutch engages perfectly and sooner than I remember the previous set up. So cause of premature wear and shudder appears to clearly be due to having had the clutch cable too tight. Lesson learned (IMG:style_emoticons/default/beer.gif)

[rgalla9146]

Completed installing the tranny with new pressure plate (Sachs 228 mm) on the aftermarket flywheel - cleaned up with some fine emery paper - and a new throwout bearing. Adjusted the cable sohat the clutch engages at about 1/3 to 1/2 distance out from floor board stop. Clutch engages perfectly and sooner than I remember the previous set up. So cause of premature wear and shudder appears to clearly be due to having had the clutch cable too tight. Lesson learned (IMG:style_emoticons/default/beer.gif)

"Adjusted the cable so that the clutch engages at about 1/3 to 1/2 distance out from floor board stop"

.....proper clutch adjustment is not determined by where you feel engagement.
It is determined by free play at first pedal motion....at the top.