SC Clutch Job on a Budget; What parts can I reuse?

b. hilliard · 08-01-2004, 08:15 AM

Hi-
This is kind of long, but my clutch troubles are driving me crazy...

I'm facing an engine drop and total clutch rebuild because I can't track down a severe clutch chatter, but I need advice!
My '78 SC had a total engine/ trans rebuild, and a resurfaced flywheel +/- 30k miles (and 8 years) ago by Gary Wigglesworth of Pennsylvania. It was done by the PO and seems to be holding up well. These miles have been VERY easy on the drivetrain while in my hands. Here's my problem:

Severe chatter in first and reverse, ONLY when the engine is very warm. I've rebuilt the pedals with bronze bushings, put in a new cable and adjusted it many times. There may be a hint of oil near the trans/ engine joining points that could be from the flywheel seal. Release arm and helper spring appear in very good condition.

There is never any slippage and everything is very smooth otherwise. I feel that if my flywheel seal was leaking, it would slip like in my old Beetles. I've re-adjusted the bowden tube, clevis fork at the pedals, and adjusted the nuts on the clutch cable a zillion times...

Questions:
1. Is there anything I can do to not drop the engine and replace all these seemingly new and good parts? What am I missing?
2. Could the pressure plate or flywheel warp for no good reason? Can I remove these and have them resurfaced and put them back in without doing much else?
3. Could a very slow leak from the flywheel seal cause the problem? Can I just replace this item?

I need help and am scared that I will end up doing a complete clutch job and have the same problems. Please keep this new member and dream car on the road!

Thanks-
Brian

North Coast Cab · North Coast Cab's Garage

Sounds like you need to drop and take a look. All parts can be reused, but it's a matter of the "while I'm in there syndrome." With luck maybe you can just replace a bad/defective dick or pp.

John

76911S · 08-01-2004, 08:50 AM

Not trying to question your diagnoses, but are you sure its clutch chatter?

Can you be more specific about the problem you are having?
Everything can be reused unless it’s not in good shape, when the work was done before was the clutch replaced? If not, how many miles are on it?

b. hilliard · 08-01-2004, 09:37 AM

there's no question it's clutch chatter... i just can't fathom that the pressure plate could warp or clutch start to fail with so few miles, especially because it doesn't slip at all. Like I noted, it has about 30k miles on the complete rebuild by a reputable shop.

When the car is cold, take up in first gear is very smooth and strong. Once the car is very hot (an hour or so at highway speeds) it is nearly impossible to take off smoothly; the clutch will grab at first contact with the pressure plate and the whole engine and trans bounces badly. Even if i feather the clutch and use more rpm's, it's difficult. Sometimes launching softly with about 1500+ rpm's will work, but i don't like to do that.
I've tightened all engine-trans connections, and all of the mounts were replaced with the complete rebuild and appear very sound...

Can I resurface this flywheel a second time with any luck?
Brian

76911S · 08-01-2004, 10:35 AM

There is a minimum thickness for a flywheel that I’m afraid I don’t know off the top of my head but it can be resurfaced as long as it’s within spec. I tend to think that there must be a problem either with the installation the last time or perhaps the wrong clutch was used or something, you should defiantly not be having the problems you are with so few miles on the clutch. It does sound like it’s time to do the drop..
Good luck..

P.S. you should replace your flywheel bolts every time.