Miffed Clutch update / more Q's

[dorhndl]

Update to my original post from ~1 month ago, car is an '87 5ktq that's been in my posession for 2 months now w/ terminal clutch slippage anytime in boost (~2psi+) - checked linkages & adjustments prior. Previous owner replaced clutch w/ Sachs PP & disk ~5k mi ago, reported slipping since day one with new hardware. Finally pulled the clutch out last night.. Discovered a lunched pilot bearing. Evidence apparent of bits passing through the clutch but didn't see anything that would cause it to hang up. Will take a closer look Monday, particularly behind the TOB. Some notables, the fingers on the pressure plate (same as old one)are a pretty shade of blue, some heat marks visible in flywheel, disk looks passable (disk / pp. are ~ 5k mi old). "New" disk looks essentially identical to the previous take out I was given w/ the car, p/n's don't match exactly however... old disk is an "035 141 033G" as expected w/ "20.1861 711 003" also visible on it, take out disk is missing the proper part number and only shows "1861 711 033".. what exactly is this number and what significance does the second to last digit have? I'm a bit uncertain of how I wish to proceed at this point. Upgrading to a complete 20v clutch would be nice but expensive.. I'm half tempted to put it back together as-is w/ just a new pilot bearing and tob sleeve (it was a bit chewed up too) to see if it will hold. I guess I don't put too high a value on my time in this case as pulling the trans out isn't a major undertaking w/ a helper and hoist. any suggestions? anyone have a reasonably priced 20v flywheel for sale? -tom

[Tom Faust]

As the flywheel has heat marks, I would consider having it milled. I have had polished flywheels which caused me trouble. It might also have warped reducing the contact area.
I don't see the pilot bearing causing the troubles you describe.
I suspect that your problem had more to do with RPM than boost level, I suspect that they are just coincidental.

[dorhndl]

Took a closer look today at the trans itself. As I suspected, the problem was in the vicinity of the throw out bearing.. Turns out the clutch release lever was installed 180 degrees out of phase. The ears are not symmetrical and the alternate orientation was preloading the TOB much like riding the clutch would.

check twice, install once.

happy boosting,
-tom

[SteveJ_in_TX]

Are you going to resurface the flywheel and re-use the parts? It is a royal PITA to pull the tranny, just curious...

-Steve Jensen
87 5kcstq
87 5kcstqw

[dorhndl]

Apparently the Germans are much more trusting of their assembly workers than the Big 3.. no way would mis-assembly of this sort be possible if this part were designed w/ the intention of the good 'ol United Against Working boys putting everything together.

While I'm sure some purists (or team doorhandle engineers) would cringe at the thought, my plan is to scotch brite the flywheel and button it up w/ new throw out and pilot bearings.

We have some useful tools at work (hoist, trans jack, large burley helpers, etc.) so pulling the trans isn't as big an ordeal as it would be in my driveway. Taking our time as it was the 1st time out, took about 2 hrs from start to "damn, gotta figure out where to put this thing since it isn't going to fit under my desk".. probably an hour's worth of work next time. I do need to find a centering tool though.. have one handy?

-tom