UncleMaz

US MY1985.

I am sure this is covered specifically somewhere...

With the help of Chris (Genikz), we pulled the clutch on my 1985 this weekend, replaced pilot bearing, and reassembled the clutch set-up with excellent used discs from 928I, cleaned up the surfaces of the IP and FW, used a recently replaced PP and release bearing out of my 80 car and stuffed the pack back in the car. In the process of installing the PP bolts, we managed to mangle the tips of a few of the bolts fighting alignment and pressure plate clamping, not damaging the flywheel threads though. The first two bolts went in with some jiggling, but the rest are a bear to get in and turn - much harder to turn than they seemingly should be.

What is the best method to clamp and align the PP bolts (we used a c-clamp)?
Should they be this difficult to get started or is something amiss?
What is the best method to seat the intermediate shaft into the pilot bearing?
Does the release arm need to be pulled back to seat the intermediate shaft or the bolts loosened?

I know DD clutch questions come up ad nauseam, but any help is greatly appreciated. Thanks in advance.

brutus

Did you put shims under the large rivet like heads BEFORE you unbolted the clutch pack ???

UncleMaz

Thanks for the reply. No I did not.

Andre Hedrick

Then you are suffering the same problem I did!
Eat your wheaties and get some long studs (3 of them) to help you muscle wrench it back together.

Rob Edwards

I think it would be easier to undo the 2 bolts you have started, remove the clutch pack and shim it. Takes all the pressure off the diaphragm, which is currently fighting you. Yes, it's painful to pull out the clutch pack again, but shimming is quick.

Here's a SD PP being squeezed to put in shims, the location on a DD PP is a bit different but same process with a C-clamp:




DD PP shimmed with bigass nails, heads dremeled off:

UncleMaz

Thanks Andre. I got your PM and will respond shortly. Thank you so much.

Thanks Rob. If this relieves pressure on the PP, this will definitely help with the install. The pictures are an enormous help.

Also, I will use this opportunity to pull out the newly installed pilot bearing and replace it with a newer one not made it China

UncleMaz

Clutch job is done!

Pre-loading the PP with nails (as shims) per Rob's suggestion turned it into a relatively easy job. Also, some helpful hints from Andre Hendrick, particularly using zip ties to help keep the pack together while hoisting it up kept my semi-greasy hands off of the friction surfaces, was very helpful. Andre was also very generous with his time on the phone.

Thanks for your help Chris (the first go around).

Thank you to 928I for the meaty friction discs -- half off!

I have been babying the former clutch since I got her on the road. It is nice to have a clutch that engages butter smooth.

Next up, install my Pklutch and service the transaxle oil (along with a million other things).

Thanks RL928! This place is invaluable.