Re: problems cont (long)

["Dan Bubb" <jdbubb@ix.netcom.com>]

Joe:
Just went through the same bullshit myself. New Sachs disc and 16V PP.
Worked fine for a while then started to not release fully. Very difficult to
shift unless I was very deliberate and matched revs.
Pulled the tranmission, inspected all the parts, replaced cable, TO bearing.
Did not fix problem.
While investigating further, because I didn't want to pull the transmission
again, I was driving the car aggresively and making sure I was pushing the
clutch pedal all the way to the floor to verify the transmission wasn't the
problem. Anyway, during this aggresive driving two of the PP rivets let go.
(NO! I wasn't dumping the clutch with big shock loads!) Sounded like I was
dragging a trash can under the car with all the little bits rotating around
the bell housing.
Anyway, replaced the PP, problem solved. Just because it was new didn't mean
it wasn't the problem.
The pressure plate is one item that the average Joe (sorry!) can't visually
inspect and tell whether it's OK or not. Mine looked OK, no visible cracks,
looked symetrical, but it was the problem.
The good news? I'm getting REALLY good at R & R'ing the transmission.
HTH
Dan

----- Original Message -----
From: Joe Doty <rocco2nr@hotmail.com>
To: <scirocco-l@scirocco.org>
Sent: Sunday, September 16, 2001 8:03 PM
Subject: problems cont (long)


> i know everyone is tired of hearing about this, but i am running out of
> ideas...many, many thanks go out to the person who can figure this one
out.
>
> first off, i have a rebuilt 9A with a kraftswerk rebuilt 4K w/.71 5th
gear.
> redline MTL, velocity (clutchnet) dual fiber disc, stock 16v pressure
plate,
> velocity lightened flywheel. all with less than 15k miles.
>
> only thing weird i ever noticed is that when i installed the exhaust cam
for
> an intake, i had a knocking noise when it was in neutral and the clutch
> pedal was out. thought nothing of it, as everything worked perfectly.
>
> the problem started out with being a little difficult between shifts, it
> sounded like it was still catching teeth when shifting out of a gear. it
got
> worse and worse, until i could no longer shift unless i revved the engine
> between shifts. then it got the point of where i couldnt get it into gear
> when the car was stopped. at all.
>
> replaced self adjusting clutch cable with manually adjusting one to no
> avail. adjusted it until there was no freeplay whatsoever in the cable.
the
> arm on the transmission was going up so far it was hitting the motor
mount.
> yet, the clutch still grabbed way at the end of the pedal travel...???
>
> pulled trans, inspected all components, nothing was broken, no bolts
> floating around, everything looked perfect. input shaft looks great.
> regreased it. reinstalled, problem still there.
>
> pulled trans again to replace thrust plate, throwout bearing, clutch
> pushrod, and the little clutch pushrod arm inside the 5th gear housing.
none
> of the parts i took out looked very worn at all. worked for a bit it
seemed,
> and then same problem came back. knocking noise from cam install is gone.
>
> checked crankshaft axial play...there is very little. moves no appreciable
> amount when the clutch is pushed in or a prybar is put on the crank
pulley.
> pulled thrust bearing, there is a .002" difference between the two sides.
> the babbit is worn off on the clutch side, but still...
>
> clutch cable has been adjusted to the point of being ridiculuous, yet the
> pedal still grabs at the end of its travel. i can actually drive it if the
> car is moving, which would suggest a problem with the clutch still turning
> the input shaft on the trans. but it will still be difficult to shift.
> reverse grinds if i try to shift into it...
>
> could it possibly be a transmission problem at this point? i babied the
> shifts as much as possible, not wishing to have to pull the transmission
for
> a long time. never raced, no rude clutch dumps. the fact that the problem
> came on gradually suggests that something became worn out.
>
> i am very confused and frustrated, and advice or ideas at this point will
be
> very appreciated.
>
> thanks
> Joe
>
>
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