Early flywheel install

pancake · 05-04-2021, 09:26 PM

I have a 2.7 conversion in my 914 using a 901 trans and early (65-69) flywheel. The flywheel was cut down to get some rust pitting out. Pressing clutch pedal in barely disengages clutch and almost impossible to get into gear. I adjusted the pivot ball out as far as possible, tried cable adjustments at both ends and even removed pedal stop for a bit more travel and still not good enough. Does the flat thick steel washer inside flywheel or between flywheel and crank? I had it inside under bolt heads and flywheel mated directly to crank. If I had it correct and assuming the flywheel is simply cut too thin, can the washer be placed between flywheel and crank to space whole clutch assembly closer to the throw out bearing?

john walker's workshop · 05-04-2021, 09:52 PM

No way! Is the release system like a 914 with a pulley, or what?

pancake · 05-05-2021, 12:32 AM

Yes, the cable goes around a pulley on side of transmission

911pcars · 05-07-2021, 10:22 AM

Perhaps an answer can be found in the following thread. There are differences with the 901 clutch mechanisms depending on whether you have a pull or push-type release system.

early 901 vs late 901 for 2.7/3.0/3.2 conversion

FWIW, it could be the flywheel wasn't resurfaced correctly. Like a VW, the 901 pressure plate mounts on a step in the flywheel. If too much material is removed from the flywheel, the pressure plate may be sitting too far from the clutch fork and TO bearing. The clutch linkage may not have enough travel for the pressure plate to disengage the clutch.

... or it could be the incorrect pressure plate and/or clutch disc.

Maybe. Hope this helps,
Sherwood

tx93086 · 05-10-2021, 03:09 PM

Do not put the plate/washer between the crank and flywheel. The clutches in these (assuming you are using your 914 transmission) are fairly forgiving. They should have removed the same amount of material from the pressure plate (pp) mounting surface as from the clutch friction area. I have seen many of these resurfaced but never enough to cause a clutch release problem. A common cause of the problem you are having is a worn plastic bushing in the release fork pivot hole. Always replace that bushing when you work on a clutch. What PP are you using? There is a 1 year only version for the 69 911S that requires a thinner clutch disk. You said that the pivot ball is adjusted all the way out. How did you adjust it? Did you put washers under it to space it out? Can you tell by looking at the release fork where it comes out of the transmission if it is spaced such that your problem is in the clutch area and not the cable? If you have an early flywheel, a early 911 (non69s) or a 914 disk, an early 911 (non 69S) or a 914 pressure plate, and a release fork with a new bushing in it, you should be good even with up to 2mm removed from the flywheel.

Another thing to watch out for is when you resurface the flywheel the inner portion of the clutch disk with the springs gets close to the flywheel bolts and might interfere. It doesn’t sound like that is your problem.

stownsen914 · 05-10-2021, 04:53 PM

I wonder if something is assembled incorrectly, or perhaps the clutch fork is bent?

There should be a little plastic cup in the clutch fork where it sits on the ball. Is it there?

Nditiz1 · 05-10-2021, 08:34 PM

If you want to measure your depth between where the flywheel bolts go I can compare it to mine. I have a new one from QSC ready to go on my 2.7 that will be installed in my 74 914. As already mentioned the washer sits between the bolt head and the flywheel. I went with a 914 clutch/PP package.