DPJ's KiwiCupra's Clutch - A real 'Bitza' problem

[Damoegan]

You had another bash at it yet mate?

 

[DPJ]

No, I haven't had time - thanks for asking.

Hopefully I'll get to it tomorrow evening.

 

[Fl@pper]

To tell you the truth, if I saw this problem again, I think my recommendation would be to take the engine/box out together and then pull the transmission off.

is on my list for next time here i can tell ya - so much easier that way i reckon

 

[Damoegan]

Fingers crossed mate.

On a different note. Did you ever get your aerial for your radio sorted?

 

[DPJ]

is on my list for next time here i can tell ya - so much easier that way i reckon

I ordered a new pushrod (£17 odd) today, I don't hold out much hope that the offending one is going to be any good after I've finished with it.

Fingers crossed mate.

On a different note. Did you ever get your aerial for your radio sorted?

No - that was the next job for KiwiCupra.

I feel kind of sorry for the poor little thing sitting there on ramps....

 

[UncleFester]

I ordered a new pushrod (£17 odd) today, I don't hold out much hope that the offending one is going to be any good after I've finished with it.

I should hope not after all the grief it's given you!!

 

[Fl@pper]

I feel kind of sorry for the poor little thing sitting there on ramps....

uh oh - mk2 owners gather round - it's happened at last

 

[DPJ]

uh oh - mk2 owners gather round - it's happened at last

Yeah, yeah. Here's me having to drive round in a fully sorted 325bhp Leon and I'm missing my mk2 8v....

 

[Fl@pper]

hehehehe they get ya like that so don't worry this place would be empty if they didn't, the worst thing is trying to explain why.

 

[Cupra Kid]

the worst thing is trying to explain why.

I honestly can't explain it, i was minutes away from buying a fully loaded V5 toledo at a steal and at the last second i drove 100 miles and bought my FOURTH MK2!!!

 

[DPJ]

Woo Hooo!

The cunning plan worked!

Block of wood between engine and bellhousing by the starter motor hole. Rope around the offside driveshaft flange. Pull on rope very hard..................

I am a happy bunny !!!!

 

[Damoegan]

At last mate

 

[warren_cox]

Well done mate. Bet that was a bloody relief!!

 

[DPJ]

Cheers guys.

Here's the offending item - holed release plate on the right with it's centre 'rivet button' missing' - and a new one on the left.

 

[DPJ]

So, I happily bashed on, oblivious of the cold.....

New pressure plate fitted to the crank. Bolts torqued up. New release plate fitted and clipped in....

But the f*ckup fairy was hiding just round the corner.

I went to put the friction plate into the flywheel to mount them both. It was too big for the flywheel. F*ck F*ckedy F*ck............ Tape measure out.

My existing clutch - 190mm friction plate on a 200mm pressure plate.
New Sachs Clutch kit from ECP - 210mm friction plate on 210mm pressure plate.

My real introduction to the vagaries of the Mk2.

 

[warren_cox]

what an absolute $h1tter. Always seems its one step forward, then 2 back.

Thing is how could you possibly know until it was off. Wonder how you'll be able to get round it - will the whole thing have to go back or will they be able to just swap the flywheel?

 

[DPJ]

what an absolute $h1tter. Always seems its one step forward, then 2 back.

Thing is how could you possibly know until it was off. Wonder how you'll be able to get round it - will the whole thing have to go back or will they be able to just swap the flywheel?

I don't know, Warren. ECP only had two listed for my engine, a cheapie and the Sachs kit - both 210mm - and Etka seems to confirm this.

I guess there are more applications for the 020 box - I need to research.

I don't know if a bigger flywheel would fit my bellhousing - I wouldn't have thought it would be cheap from the dealer. (Dealer friction plate would have cost more than the whole Sachs kit - which was £86.10 )

*I really should have compared old with new before I fitted the pressure plate - I would do normally - in this case I didn't think there were any other permutations of this weird clutch arrangement......

 

[DPJ]

All the research I've done this evening suggests my clutch is a bit of a bodge-up and maybe not original.

I'm guessing the flywheel and pressure plate is off a 1.6? But why fit an undersized pressure plate?

In order to make this work, I'd need a 210 flywheel - which is 5mm larger radius than the current one......... Would the starter motor still work on it...??

I'd better double check my engine number - and the dia of the gearbox input shaft...

Any comments are welcomed..

 

[Fl@pper]

i got the 190 friction plate as a 1.4/1.6 and the 200 pressure for some 1.6's and diesel ????

send us ya engine and serial codes and numbers dude we will dig it out for ya

 

[DPJ]

Thank you, sir!

I'll have a look at the engine number on my way to work tomorrow morning - whereabouts on the block is it please?