Ford Bronco Clutch for 944
 

Just got fabricated Ford Clutch installed and it works great. Here are the pics of the build.

nice!! would love more info!

Yea whats involved.

looks like he used spacers to offset the hub of the clutch since the stock bronco clutch will interfere with the flywheel bolts

Y?

Regards,

doug
Waterloo, Ontario Canada, eh


86 951 (http://www.pcaucr.org/index.php/visu...egory&catid=61)
01 E320 (W210) 4-matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers

$$

O.

Regards,

doug
Waterloo, Ontario Canada, eh


86 951 (http://www.pcaucr.org/index.php/visu...egory&catid=61)
01 E320 (W210) 4-matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers

The recipe came off of a 924 forum. The 924 does not need to be spaced but the 944 does. I did as much research as I could and did not find anyone who said they did this and were disappointed. One guy said he drove his 25k miles and had to tear the car down again for another reason. He said the disk looked very good yet. I really think this is the answer to inflated prices on the 944 clutch. The disk is $30 bucks at Advance auto, I beleive I asked for a 1985 Ford Bronco 2. Make sure to look for the 18 rivits so even if you just use bolts to reassemble it will be plenty strong. It needs to be spaced out about 1/2 in. The guy that did mine says he can build these for $110. He used machined aluminum spacers. That is the price of the disk, money for supplies and about 1 hour of his shop time. That is about 1/2 the price of the cheapest 944 disk out there so I think it is a great way to go. I used my old PP and FW and had them resurfaced. A very good used TO bearing was found from a salvage house that had about 10 to choose from, it feels like new. I installed new pilot bearing and RMS. Used existing fork bearings and repacked them. I have no worries about anything we did holding up for the long haul and it cost about 1/3 as much as the cheapest kit out there.

Would this work on a 944 Turbo?

How much power can it hold? Bronco 2's only made like 130 HP with the v6.

I'd be worried bout (what looks like) aluminum rivets. Maybe BFBs (big bolts) would work, like in the CV.

Regards,

doug
Waterloo, Ontario Canada, eh


86 951 (http://www.pcaucr.org/index.php/visu...egory&catid=61)
01 E320 (W210) 4-matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers

The only way that Aluminum would not be strong enough is if it starts to melt. If I think that happens over 1000 degress F so no worrries there. The Alum does not warp or expand at all either. I think you might be underestimating the strength of thick aluminum.

I did that same mod a few years back on my 86T. IIRC I machined a solid spacer ring 5/8" thick to make sure it cleared those funky cheesheads and used 12.9 threadlockers. And yes the Porsche disc is too much. Now you guys need to find a "puller" pressure plate and stick a fork in this pig.

Do you mean it doesn't expand due to a temperature change? I disagree with that. The thermal expansion for aluminum is .000023 per degree Celsius, a 1 meter bar will grow 2.3 mm if its temperture increases 100 degrees C.

That is negligible on a 15mm thick T-6061 T6 ring/spacer. The disc splines will walk the TT shaft way more than just by centrifugal force and vibrations.
I was looking at the Broco pressure plate and wondering if it can be used, the TO bearing looks similar to the 944 as well. would be worth doing a comparo as performace Bronco clutches are now made for cheap.

I really believe the setup we used is twice as strong as it needs to be. Probably a lot stronger than the original rubber setup the car came with.