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

DPJ

...........
Dec 13, 2004
7,996
2
NN Yorks / Salento
www.seatcupra.net
Well, we've spent today with the assumption that the correct flywheel will go with my new Sachs AGG Clutch kit to solve the problem.

Tonight, however, I measured the friction plates.

Sachs 210mm AGG clutch - (new) - for a 21mm gearbox input shaft.

and the friction plate that's been on my car - it's for a 19mm gearbox input shaft. :censored:

It would seem the car has had a replacement (ex scrappie) gearbox (not intended for a 2.0 8v) and they've cobbled together a clutch to suit.

Dilemma - what to do :think:

I've had search of the gearbox tonight by torchlight but haven't found a code - I'll have to clean it off tomorrow night and try again...
 
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wild willy

wild willy

Full Member
Aug 4, 2003
2,323
0
Wales
Complete bummer Dave, if it were me i think i'd try and source a recon or good second hand gear box of the correct original type.
 

DPJ

...........
Dec 13, 2004
7,996
2
NN Yorks / Salento
www.seatcupra.net
Cheers Pat! Worth investigating. :yes:


Edit... Passat runs a 225mm clutch on 2E...

Wrong type of change I think. :(

Fl@pper - am I right in thinking it's got to from amongst DFQ/DGE/DFP/DFW/DFN/DWY ?

DFP = AAZ diesel ebay
DFW = AEY Diesel ?
 
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Fl@pper

Fl@pper

Back older greyer and less oilier but always hope
Jun 19, 2001
12,368
25
Gloucester
all depends on the diff ratio really

if ya on to gearboxes now i would avoid diesel at first if only for the reason they are very very long geared

i prefer it myself as it suits my driving but others might not for a sporty feel

there's a ratio spreadsheet somewhere on the site i think Cymru_dave did listing a few options ill dig it out and do some standard comparisons

let me knwo when you find what box you have got so i can use that as a start guide and any i work out/find ill be able to list what will be different
 
olethalb

olethalb

ibiza gone!!!
Oct 9, 2008
252
0
bracknell
Sounds like you've got a mk2 golf 1600 or mk1 gti box on there (they all fit) if it's a pre '88 box you are better keeping it and finding the bigger clutch to fit as they are stronger boxes. there is a crossover somewhere along the lines that means you can run the larger clutch on the smaller (19mm) input shaft.

i've done loads and loads of 2.0 8v (among 100's of other boxes/ clutches) but i haven't been in the trade for 4 years now so can't give specifics i'm afraid.:(
 
olethalb

olethalb

ibiza gone!!!
Oct 9, 2008
252
0
bracknell
i used to rebuild gearboxes for a living and one of the most common cars we were doing at the time was 2 litre 8v golfs (mk3 gti's) and having owned 4 myself.

when a customer came in and was told the box needed replacing (usually due to diff failing and bits of it making their way out via the casing) if they wanted a cheap fix - not a complete new box then we'd fit mk2 golf gti boxes as they were stronger.

usually the clutch was fine but some (possibly retro fitted) had the smaller input shaft which when you found the clutch to fit the input shaft it was the smaller diameter, it would work fine for a period but would obviously wear alot quicker so was not an option. after some searching and many returned clutches we found a large diameter friction plate which fitted the smaller input shaft.

i only skimmed through the thread so may well have misunderstood, if so my apologies.:shrug:
 
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