Broken Clutch WTF!
 

My clutch decided to explode. The symptom was a dragging clutch, no matter the position of the pedal or how I adjusted the cable.

This is a new one to me. One of the 3 flat springs on the pressure plate broke.

This is a Sachs powerclutch, about 1 year old. AL pressure plate.

Here is the busted flat spring, or at least what remains:
http://forums.pelicanparts.com/uploa...1150605881.jpg

This is how it is supposed to look:

http://forums.pelicanparts.com/uploa...1150606148.jpg

It pounded my bell housing:

http://forums.pelicanparts.com/uploa...1150606229.jpg

It left a white haze on a variety of parts:

http://forums.pelicanparts.com/uploa...1150606303.jpg


http://forums.pelicanparts.com/uploa...1150606319.jpg

I figure the haze was from the magnesium being pounded by the flat spring - either creating an aerosal, or perhaps actually burning the dust.

All very strange.

I figure the clutch should be covered under warranty. This seems like a material defect to me.

Whoa - that looks pretty scary - being 1 year old I would have it back to the shop without doubt, good luck convincing them you werent drag racing :D

Hope you get it sorted chuck and that the case isnt too damaged.

Ouch! Looks like a rivet let go and the centrifical force threw the spring outward. I agree that clutch was defective from day one.

The white haze looks like burned magnesium. Magnesium is great at heat sinking like aluminum so it's rather hard to get large pieces to ignite but when it is chewed into small pieces it's very easy for it to ignite since the heat has no where to go. It leaves a white residue after it burns.

I was working with magnesium once and had a pile of shavings on the ground so I decided to see if it would burn so I put a Mapp torch to it and it lit right up. Looked like I lit a sparkler and left the same white residue.

There must have been a nice fireworks show going on in that bell housing. :)

Re: Broken Clutch WTF!
 

From the looks of the friction surface, it looks like the PP was gently used/not abused. Let us know what Sachs says.
-Chris

Chuck,
I seen this failure many times with Sachs clutches. I curently have a 04 GT3 in my shop with the same failure and consequent trans damage. The GT3 had an uprated Sachs unit with very easy use. Good Luck with the warranty :rolleyes: If you look at the Centerforce clutches for Porsche they are Sachs bodies with these very pieces replaced ( and higher rate diaphragm spring). We've had good luck with them in high hp cars.
Dan J

Hmmm, I'd say Sachs owes you more than a prorated clutch.
Can you say callatoral damage and labor hours?
Please post the net result, as this would certainly impact others decision on which clutch to purchase, should the need arise.
Hopefully, Sachs would treat you fairly, do to your stature within the community, and your ablility to recommend/or not to others.
Best of luck to you Chuck!

The bellhousing looks pretty well reamed. Possible loss of integrity there or can it still be used with confidence?

Yes, it hammered the bellhousing pretty badly. However the meaty sections were the bolts secure the housing to the engine are still intact.

I've put it back together with a new clutch and I am going to give it try. I'll be monitoring the housing, inspecting for cracks regularly.