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"So what pulls the actual pressure plate down when the TOB pulls on the fingers? Is the PP actually attached to the outside of the fingers? How is it attached because I didn't see any bolt or other ways to attach it."

I've never had one of these apart but the diaphragm spring is usually secured to the cover (the part that bolts to the FW) somehow out near the circumference with a pivot attachment then the circumference of the spring is held underneath a lip of some sort on the pressure plate itself. The geometry is such that a relatively large movement of the TOB acting on the spring fingers results in a very small movement of the circumference of the spring which pulls the plate away from the disc releasing the clutch. The setup has to be a little different on this since the TOB pulls on the fingers vs. normally pushing on them but the principle is the same. You deserve a medal after going thru this.

Last edited by boosted79; 06-09-2015 at 12:44 PM.. Reason: spelling
Old 06-09-2015, 12:42 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #161 (permalink)
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Thought I would check in after a while..I've missed the community! I recently moved on from my third tour of duty at Patrick MS. During my time there I dealt with thousands of clutches and have some experience to share that might be helpful.


Reading a good portion of everything going on with this but not the middle pages...
The few pictures I see but didn't see part numbers or summary? It can only be a certain number of things and hope your level of frustration isn't to the throwing wrenches stage. Hope this helps and apologies if I missed the part numbers to check!


Looking first to not original parts list:

1. My first thought is incorrect disc thickness. There are a few different thicknesses and part numbers to properly match with the pressure plate. ~10mm for most stock 76-89 (930/G50) and ~8 mm for (Sachs Performance).

The Sachs Performance (RUF 5 Speed Disc) PN: 88 1861 999 615 is thinner at ~8mm and designed to work with the matching pressure plate (RUF 5 Speed / 934), NOT any stock 76-88 pressure plate. If you have a HP pressure plate with a stock disc, that is a no go. It is really unlikely SACHS messed this up..they are really tight QC / ISO these days. In my experience these disc applications get messed up sometimes with parts vendors as the stock photos are sometimes showing wrong or older parts.

2. My second thought would be flywheel resurface. The pressure plate mounting surface and disc friction surface both need to be min cleanup cut..this is likely correct but worth mentioning. The flywheel has a machined groove near the outer bolt ring..this is an indicator of min thickness.

3. Third the other thing that sometimes happens with introduction of a new lower profile pressure plate is the limit pins can bind on the underside of the ring gear. The earlier ring gears (low profile) have 3 clearanced hole features. You have a MODE starter ring gear extension and release bearing extension. The ring gear extension features the same larger clearance holes so this is not the problem.

4. The other not so likely event is the damage of the pressure plate diaphragm due to over-stroking. Not likely but they can get tweaked.

Hope this is of constructive help!
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Old 06-09-2015, 03:52 PM
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Quote:
Originally Posted by Kraftday View Post
. . . damage . . . due to over-stroking.


Thankfully, I haven't experienced any notable damage . . . yet!!!!
Old 06-09-2015, 06:42 PM
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Jeff, don't know when you're back, but your new Sachs pressure plate is slated to be delivered to your office Friday.
Got the other one back, and we're forwarding it to Sachs, see if they'll test it and share results.
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Old 06-15-2015, 05:56 PM
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Great Success!!

I got the PP today as promised by Chris. I blew off my GF and went to work. First I tested it on the hydraulic press and all three pins compressed at exactly the same time, so I cleaned the flywheel, PP and disc surfaces, carefully installed it on the motor, greased the fork, the splines and the TOB collar (lightly this time), torqued it correctly, and installed the trans. I then tested the clutch release with a long bar pushing the long clutch lever until the TOB was just about all the way to the trans and then spun the friction plate with a long screwdriver. NIGHT AND DAY difference. It turned easily, which the old one never did.

I am so relieved.

So now I get to put the motor back in this weekend and hope I don't screw anything else up in the process and get this puppy on the road.
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Old 06-19-2015, 09:27 PM
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Great, what a PITA that was. Makes one question Sach's QA program.
Old 06-20-2015, 05:29 AM
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whoa - WELL DONE JEFF!!!!!

what an ordeal, way to persevere

lookin forward to hearin about yer shiiteatingrin @ 1st WOT heh heh

now, most importantly... see you 7/23 then, jah! Muwhahahaaa...
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Old 06-20-2015, 05:42 AM
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WOW Jeff, sounds promising - hope to see a good report once you've got the engine & paulmission back in the car!
Old 06-20-2015, 11:12 AM
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It was the moth with glowing eyes...
it's probably gone now and took it's spell with it.

Good luck with your car, I'm looking forward to hearing more about it.

Last edited by JFairman; 06-20-2015 at 11:08 PM..
Old 06-20-2015, 05:24 PM
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Thanks guys. Yes it took a lot of perseverance to keep going until I figured it out. I was so nervous when I went to check that the friction disc was able to spin correctly. If this wasn't it, I would have been crushed.

Out of an abundance of caution, I did not let my daughter film any moths while I was installing the clutch.


Got it together and motor is ready to be reinstalled:

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Old 06-20-2015, 10:49 PM
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Good luck, Jeff. I look forward to hearing the good news.
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Old 06-21-2015, 05:04 AM
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Jeff, while digging around for clutch adjustment threads I came across this one. At the risk of igniting any lingering PTSD issues, did you ever hear from Sachs on what their findings were?
Awfully good on Chris at TK as usual- I hope Sachs warrantied it and he didn't have to absorb the replacement cost.
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Old 06-20-2017, 05:26 PM
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Hey Ken,
I never did hear back. I did talk to Chris a couple weeks afterward and he said that he did send it back to Sachs, but couldn't promise they would ever give him a cause. Maybe if he sees this thread and heard back long after I was up and running he can post up any findings.

The clutch has been flawless ever since and I am happily putting miles on the car without issue this year, so no PTSD for me, LOL.

Yes, Chris was helpful and patient with me the whole time. I do hope that Chris was able to get Sachs to refund his money for the defective PP.
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Old 06-20-2017, 08:43 PM
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