Clutch issues.....

[Gumba11]

Hey guys,

I have now installed the engine and trans back into my 77 930 using a stage 2 KEP pressure plate and their "Race Organic" disk.

I have installed it no differently than any other clutch I have done but no matter where I adjust it to I cannot seem to get it to release. The fingers of the fork are properly engaged to the T.O. bearing and I have an access hole in the top side of my bell housing I can reach my finger into and when the clutch pedal is pushed I can feel the fingers of the pressure plate moving so I know it is working.

Is it possible that a stage 2 disk is thicker and there is a different adjustment method that needs to be done? I really dont want to have to pull the engine and trans back out but at this time I dont see any other options.

Help?

..............................................Chri s

[Porschephd]

Some of pressure plates have issues with the rivets hitting and not allowing the PP to release. Call KEP and ask them if your PP falls into this issue.

[dean]

I got a PP from KEP where they forgot to machine reliefs in the PP.

It kinda pissed me off cause they expected me to pay for shipping the unit back for machining. Plus I had to figure it out and it took me 4 times R&Ring the motor with a torn rotator cuff to figure it out.

[Gumba11]

Yeah, Im not really happy with them at this point. I have already been sent the wrong clutch disk on a time critical project! I will keep you guys posted on what I find.

Thank you!..................................Chris

[Gumba11]

So I talked to KEP and they tell me they have not had issues with any of their 930 clutches in years. I was told the disk is the factory thickness. I pulled my engine and trans again last night and looked at the clutch package. The only difference I see between the two pressure plates is about an 1/8 inch difference in the hight of the PP face, meaning the KEP pressure plate would take more pedal movement or more aggressive adjustment to get it to disengage.

I am beyond confused on what to do to resolve this issue and KEP isnt too excited about helping either.

Any thoughts? Can someone tell me what a new 930 3.0 Litre 6 bolt crank clutch disk should measure for thickness?

Thanks for any help here.

.................................................. ..Chris

[David]

All I can find is 10.1mm, but I don't know if that's good for '77.

[Gumba11]

Thanks David!

[rg500930]

when your in the car and push down on the clutch peddle how does it feel,normal?i dont know what stage mine is.got it years ago.but its abit stiff.i had to reinforce my clutch peddle.it was bending so it wasnt disingaging all the way.and while your down there spray grease into the clutch cable.made a big diff for me

[Gumba11]

So Im sending all of my KEP product back for a full refund. They dont know what is wrong with the set up. I was told today that they dont do alot of turbo clutches from the owner him self. At this point after 4 engine drops trying to figure this out I am beyond frustrated and have decided to try a Sachs "Power Clutch" instead.

I am amazed that a company that has been doing Porsche clutches as long as KEP seem to be unable to help me with my technical issues.

End result is the clutch disk is too thick and the pressure plate appears to be machined incorrectly.

Very disappointed to have wasted 2 weekends now trying to make this thing work.

Just wanted to give an update and warn other turbo owners of the issues. Buyer beware! Make sure you ask all the questions you can because even that might not be enough.

.................................................. .Chris

[ManaMan]

Thanks for posting about this....I have my new flywheel and was considering buying KEP clutch and PP. I won't now...good timely warning.

[sand_man]

So sorry to hear!! GAWD, how frustrating for you!

When the original rubber centered disc in my '87 took a big dump, I thought about going with KEP - used them on some highly modified early VW air-cooled engines that I built - but I was unable to get a "warm fuzzy" about using their products on my Turbo. I ended up with a factory PP and the early 3.0L Turbo spring centered disc. Of course my engine isn't a 600HP EFI monster either, but with about 350-390 at the wheels I haven't noticed any slipping, so it's served me well, for my application.

[dean]

Hey Chris,

Why don't you have KEP look at the PP then decide if you want to dump it. I think I know your frustration level now, but if you get the KEP thing figured out you will be happy with the clutch.

I am not sure the Sachs will hold your power, so you will be changing that soon anyway. And paying for a new clutch.

Good luck

[NathanUK]

I think the Moral of the story here is to buy your parts from Stephen of Imagine Auto. He inspects the parts he sells and if they are not to his standard/spec he sends them back. If you did have a problem with a part he sells you he would help you to the very end anyway.

[David]

I'll second the vote for Stephen. When I've had a problem he's taken care of it. And when I'm too stupid to figure out the obvious, there's a decent chance he'll answer the phone after hours and straighten me out .

[Gumba11]

I have done business with Stephen before and I think he is great but for budget reasons I could not afford to get it from Stephen and went direct with KEP.

This is a problem that a simple visual inspection would not find according to KEP. The pressure plate must be intalled in a press and clearances as well as total travel must be measured. I dont think even Stephen would want to go to that point with every clutch he stocks.

I might go with an upgraded disk and Power Clutch PP to get some added bite.

As for KEP I have wasted 2 weeks on this and need to make something happen and be ready to go to a national show in Idaho with the car. I want it to be running for this show as it is one of the largest I attend throughout the season. KEP should have asked for the parts back the first three times I called them but rather than that they offered me very little tech support until I talked to the owner.

Thanks for your thoughts guys.

................................................Ch ris

[The Turk]

Sounds unusual that the fingers are moving but the clutch won’t disengage.
Don’t take this wrong… Is there any possibility that the disk got put in backwards ?
I think it can be done and the result would be that it would hit in the center of the flywheel and bind on the surface of the pressure plate, it wouldn’t disengage even though the fingers were moving.
I was told that the disk needs to be 10mm thick when I did mine.
I used the Sachs aluminum 935 pressure plate ($1400) and a Cluthnet organic street/track disk, my disk measured 9.25mm thickness and after only 600 miles has started to slip a little when the boost hits in 3rd,
I’m not sure if it’s the disk is too thin or not enough clamping force by the pressure plate, the plate was suppose to be good to 700hp.
Keep us updated to what ends up working for you.

[A930Rocket]

I've tried to place a disc in both ways. It will only fit one way.

My new (stock) spring centered clutch has started to slip when it hits 6200 rpm. I've adj the arm several times, but it keeps happening. Maybe the new motor is too much? I'm making 400 rwhp, but heard/thought it could handle it.

[Gumba11]

My current plan is to get a Sachs spring center disk and compare thickness with the KEP unit. If the Sachs unit is thinner I am going to try it with the KEP stage 2 PP and hope that it will work. If not then I am going with the Sachs PP that was in the car prior to EFI. If needed I will detune the car to make it work until I can get a better clutch solution.

I will keep this thread updated with my findings.

Thanks for all the help guys. This has been beyond frustrating. Its nice to know there is plenty of good advice here.

.................................................. ....Chris

[Tom F2]

What's wrong with the factory clutch, Chris?

[Gumba11]

Factory clutch wont handle 500+ RWHP.