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Discussion Starter · #1 ·
need some advice...clutch engagement related

OK, this damn single mass conversion is driving me nuts...and as always I choose the hardest route possible.<p>So I got an evo clutch kit...the splines are a bit different, but wth, my tranny is on the last leg anyway, might as well try this out.<p>Here's the pp+fw:<br><IMG SRC="http://i161.photobucket.com/albums/t215/rushin_album/DSC03630.jpg" BORDER="0"><p>already found a shop to do the re-pinning since the mounting points are 1/8" off. Here's my final problem:<br><IMG SRC="http://i161.photobucket.com/albums/t215/rushin_album/singlevsdual.jpg" BORDER="0"><p>as you can see, if I throw everything as is, the slave won't reach the PP. So I'm thinking of a few solutions, just wanted some input before I do something dumb...well, too late for that...but anyhow:<p>A: Machine a 20mm spacer to go on the throw out bearing.<br>my concerns( too much mass, possibly throw everything out of balance when disengaging clutch. also possibility of the thing falling off and doing who knows what)<p>B: Same as A, except the spacer will attach to the pressure plate instead of the throw out bearing. same concerns, harder to balance.<p>C: See if I could physically bend the pp fingers 20mm up.<br>this kind of just hit me, but seems plausible. My concerns with this solution is possibly breaking the fingers, or if bent uneven...the clutch won't release evenly...blah, blah...leading to premature clutch failure and all that good stuff.<p>Soooo, any advice? <br> ...and please don't tell me to just go w/ the stock set-up, or get a pp with taller profile...b/c I just won't listen <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/tongue.gif" BORDER="0"> <p>BTW, I also had an idea to convert to an external slave, but that's for another topic. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0"> <p><br>Edit: meant to call the thread clutch engagement...not engineering<br><BR><BR>
<i>Modified by rushin_max at 12:00 AM 8-7-2009</i>
 

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Thicker throw out bearing. <br>Go to bearing manufacturer or warehouse and buy stock plus X mm (as needed to replicate stock dimension.) <p>Can you add a pic of the stock bearing and how it attaches so we can consider any attachment issues<p><br><i>Modified by JDS60R at 10:09 PM 8-6-2009</i><BR><BR>
<i>Modified by JDS60R at 10:10 PM 8-6-2009</i>
 

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Discussion Starter · #3 ·
Re: (JDS60R)

Can't post any pix right now, but look in this thread to get an idea...<br><A HREF="http://forums.swedespeed.com/zerothread?id=122191&postid=1283419" TARGET="_blank">http://forums.swedespeed.com/z...83419</A><p>the bearing has a seat that extends down a bit and also acts as a stopper when fully extended, so that might be a problem.<p>I was thinking machining a tight fitting cap and epoxy that sucker just for good measure(can't weld, will melt the plastic)....but 20mm of metal is gonna be some weight, so not sure about that.
 

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Discussion Starter · #4 ·
Re: (rushin_max)

ok, replying to my own post...finally came up with the solution. Here's what you need to make:<br><IMG SRC="http://i161.photobucket.com/albums/t215/rushin_album/adapter.jpg" BORDER="0"><p>Right on Max, thanks.<p>No problem, glad to help myself out.<p> <IMG NAME="icon" SRC="http://www.vwvortex.com/zeroforum_graphics/screwy.gif" BORDER="0"> ...i need a <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/embeer.gif" BORDER="0">
 

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Here's how I did mine.<p>The splines are different between the -01 and the 01+ trans due to the stock dual mass flywheel setup.<p>Here's the '95 trans that was originally on the '95 yellow t-5r:<p><IMG SRC="http://upload.awineshop.com/files/8/IMG_7944.JPG" BORDER="0"><p>Here's the '04 S60 trans, which coincidentally is the same as the M66 input shaft! It's also what's on your trans:<p><IMG SRC="http://upload.awineshop.com/files/8/IMG_7945.JPG" BORDER="0"><p>I found an off the shelf 9-3/8" disc that originally fit a (gasp) '85 Ford Mustang!!! Here's the mustang disc and the 272218 850R clutch disc side by side:<p><IMG SRC="http://upload.awineshop.com/files/8/IMG_7932.JPG" BORDER="0"><p>Apparently it had been sitting there for a long time (15+ years). I got an awesome deal on it because it had been sitting there forever. Notice the center spring carrier of the disc is much larger, and this required some machining on the disc surface:<p><IMG SRC="http://upload.awineshop.com/files/8/IMG_7936.JPG" BORDER="0"><p>And yes, I am using the T-5R Clutch Pressure Plate.
 

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Discussion Starter · #6 ·
Re: (yanger)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>yanger</b> »</i></TD></TR><TR><TD CLASS="quote"><br>Here's the '04 S60 trans, which coincidentally is the same as the M66 input shaft! It's also what's on your trans:<p><IMG SRC="http://upload.awineshop.com/files/8/IMG_7945.JPG" BORDER="0"><p></TD></TR></TABLE><br>Is that m56(5speed)?<p>M56 has 21 splines and m66 has 23, so not compatible. <p>That picture got me curios though, it looks like your new tranny uses internal slave/tob(noticed the screw) and still has a cut-out for the fork? <br>How is that part covered up?<p>BTW, thanks for trying to help but I'm afraid it's too late. I realized I had the wrong clutch type all along(pull vs push). So now I ordered the Sachs 707 plate for audi s2, and everything matches up perfectly. It has taller profile than oe plate, so no spacers required! ...updates will come as soon as I get my new diff. and put everything back together ....hopefully really soon(fingers crossed).
 

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Re: (rushin_max)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>rushin_max</b> »</i></TD></TR><TR><TD CLASS="quote"><br>So now I ordered the Sachs 707 plate for audi s2, and everything matches up perfectly. It has taller profile than oe plate, so no spacers required! ...updates will come as soon as I get my new diff. and put everything back together ....hopefully really soon(fingers crossed).</TD></TR></TABLE><p>would very much like to hear a full story on this<p>consolidate all your threads into one?<p>like...<i>I stripped my collar gear, which messed up my transmision, and while I was there I decided to replace the clutch, but then decided to go crazy and get an evo clutch, ....scratch that Audi clutch ...and yeah I had to fabricate a few key pieces for it but it works like a champ and now my drivetrain is not made out of glass. I have a single mass flywheel, a manly man's external slave, and the collar gear is welded in place. Volvo should hire me because I'm awesome </i><p>BTW I just made all of that up...
 

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Re: (rushin_max)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>rushin_max</b> »</i></TD></TR><TR><TD CLASS="quote"><br>Is that m56(5speed)?<p>M56 has 21 splines and m66 has 23, so not compatible. <p>.</TD></TR></TABLE><p>the older m56s have 22, and the newer ones have 23. That one above has 23.
 

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Re: (FEO)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>FEO</b> »</i></TD></TR><TR><TD CLASS="quote">like...<i>I stripped my collar gear, which messed up my transmision, and while I was there I decided to replace the clutch, but then decided to go crazy and get an evo clutch, ....scratch that Audi clutch ...and yeah I had to fabricate a few key pieces for it but it works like a champ and now my drivetrain is not made out of glass. I have a single mass flywheel, a manly man's external slave, and the collar gear is welded in place. Volvo should hire me because I'm awesome </i></TD></TR></TABLE><br>Great improv'. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/cool.gif" BORDER="0"> <p>Max, I'd love to get the cliff notes to the full story as well. <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0">
 
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