G50 Conversion - Help !!!

[Natchamp]

Ok, I am getting ready to sell the beast (notice the small b) for $1 becuase of the level of frustration! As many of you know I have been working on a G50 conversion, which has been no small task. I'm not even going to list all the issues/problems but the latest is having to pull the motor and tranny "again!" because the input shaft of the G50 was slightly too long and bottoming out againgst the through-out bearing. It took a while just to isolate the problem.

After fixing that issue and installing the motor again everything looked good. It was really good to hear it run gain. Now the problem:

The clutch does not fully dis-engage. I have bled the clutch cylinder and the pedal "feels" very good. When you depress the clutch pedal it feels like the clutch is dis-engaging and actualy going past the point of dis-engagement (spring pressure falls off). However, it won't go into gear and I can't push the car when in gear with the clutch depressed. I am using a stock G50 steel flywheel, Sachs aluminun pp and sport disc.

I have searched the archives and only found one relevant thread where someone actually had to shim the pp. I am not looking forward to pulling the motor again. This weekend I am going to try and get up in there and visually see how much travel I am getting at the pp levers, etc.

Does anyone have any clues for me for what to look for or what I can do?

Signed, currently a little beaten pussie cat, no beast!

[orbmedia]

Maybe a photo of your setup? Perhaps you need to alter the length of the lever arm on the clutch fork. I assume you are using an external slave cylinder with some sort of home-made bracket and not one of those concentric slave cylinders?

[Natchamp]

The slave cylinder, arm, etc. is all stock Porsche stuff. The only non stock part I am using is the master cylinder but I am pretty confident it is set up correctly and It has enough throw. It's very perplexing.

[orbmedia]

Sorry I was thinking 930 trans for some reason and assuming a hydraulic conversion.

How about the hydraulic plumbing? Can there be flex in there that is taking away your travel? How did you run the lines from the pedal to the slave cylinder?

[LeeH]

Patrick Motorsports here in Phoenix claims to specialize in g-50 conversion. There's not a lot of info on their web page, but they might be worth calling.

http://www.patrickmotorsports.com/g50.html

[Oliver911]

The only other thing I can think of, provided you are positive there is enough travel for full diengagement, is a frozen clutch disk. The chanches of this are slim, but it happened to me on a 71 911 that was sitting for 20yrs. The symptoms are exactly as you describe. One solution is to jolt the clutch by starting the car in gear, it may take a few tries. I know this is really reaching for a solution, but I would give it a shot.

[JohnC]

Ive had the same thing happen but on my V6 vega. The combination of the new fly wheel, clutch disk and heavier pressure plate would cause the disc to "stick" to the fly wheel.
I solved the problem by having someone depress the clutch pedal and I pried the clutch disc off of the flywhell using a screw driver. Once the new flywheel and clutch disc had a little wear on them....no more problems.

[Thomas Owen]

Tell us more about the master cylinder...not a Porsche item? Are you sure you have the equivalent volume of fluid being moved through the tubing when the pedel is depressed as a stock G-50 setup?
Good luck,

[Natchamp]

Thanks for all the suggestions, I think I got it figured out. One of the previous problems I had was that the ring gear that I was supplied with didn't have the relief holes in it for the pressure plate"plunger thingy bobbers" that move when the clutch is depressed. So I simply drilled holes in it so they could move. I think one of the holes isn't letting the thingy bobbers move. One of my freinds came over tonight and we checked it while one was under the car looking while the other slowly turned the engine over to each thingy bobber location.

So, I am going to try and losen all the pp bolts to let the ring gear move a lttle bit to get them all to be able to move. If that doesn't work, I'll have to remove the engine again. Heck, I've done it soooo many times, now I just throw the tolls near the car and it practically falls out. I'll keep you posted.

So, the price just went up to $2 dollars.

[tobluforu]

I don't know a damn thing about what your doing, but I was at the racers group at sears point and they did the same conversion on a 73 with a 3.6 putting out 340hp. Great bunch of guys. You could give them a call. They are more than willing to answer any questions.

[Nader]

I will give you $10, and we can end this auction early. I offer this despite common sense telling me to get a PPI.

[PorscheDV]

DONT LISTEN TO THEM MARK!

i'll give you $50 and i'll clean your garage!

[H20911]

congrads Mark!
this was one of the many problems that I ran in to but in my case I had flipped the starter ring gear and the hole was in the wrong location.

But frustation is when you pay an A hole $2800 for a used turbo 4 speed (long box) then give him another $500 + your 915 box to shorten the 4 speed. He cuts it and the input shaft too short so the pp bottoms in the bellhousing. He then makes an adapter plate to shim it out (Too far) then you strip 3 starter ring gears at 410 dollars a pop .....make your own trans mount .......make a throw out bearing extender......you then buy another 915 to put in so you have time to work out the bugs with the 4 speed....................Argh!!!!!!!!!!!!!!!!!

today I took it for ride for the first time with the 4 speed . I have to take it easy for the first 500 miles so the kevlar clutch can break in. Under light accel. I heard a whirring noise in 2nd when I was at cruise in 2nd I could not hear it. anyway the frustration never ends.

Good luck!

Ps I took my engine out 3 times last week alone.

[Natchamp]

H2O, wow, we can relate to each other. It is frustrating indeed. Glad you finally made it "to the street". I think next time I'll just buy new 911 and be done with it. Naaaaaa. Where's the sense of acomplishment in that? It does feel good when everything works out.

Sorry guys, the price of the Beast just went up a little bit. I pulled the motor (again!) yesterday and finally got things right. Finished about 1:00am and took it for a trip around the block. I have to adjust the clutch but other than that everything looks good. The shifting of the G50 is incomparable to the 915. It is unbeleiveable. I will post a longer debreifing when I've really got it dialed in. The regearing of 1,2,5 also appears to be spot on.