Tampa 928s

78 928
I was given a 82 clutch pack complete except for the guide tube the rear clutch disk has a longer snout then the original. The guide tube will not go forward enough to install the pack due to the longer length of the rear disk. Since the early years have spacfic disks from 78/80/and above along with the intermediate plate attaching differently the question is the bell housing different. I thought this would be an easy replacment I would like to use this 82 as is, any advice?

toofast928

It should be a direct swap. I used a 1978 PP in my 1982 for years.

Tampa 928s

Well the rear 82 disk is longer and a shorter guide tube would work but I believe they are all the same length. Not sure why yours worked and mine does not it does have a larger ball cup which may mean it was a later year replacement.

These are the numbers on the original disks.
1864841103
1864342003
These are the numbers on the 82 disks
1864341203
1864342203

Landseer

The wsm clearly identifies the 78 tube being different dimension by a mm or 2, you've seen that, right?

Tampa 928s

No I missed that are you referencing the guide tube. The parts catalog only shows one guide tube from 78-82. It needs to be more then 2mm shorter if that's the case. I will do some more research but the differences is the rear clutch disk length and how the assembly mounts to the flywheel. The 78 has rear mounting bolts for the ring gear replaced by rivets on the 82, this makes it much easier to replace as a unit. I would like to use the 82 assembly but need to make sure the guide tube is the only issue.

Mrmerlin

posting pictures sure would help

Landseer

See WSM pg 30-13, -14, -15, -16 and 30-16a.

Original guide tube was discontinued in Dec 80. . it was 50mm. replacement is 49mm. Possible to grind-down the longer one ( modified early one ).

book tells what part numbers of the clutch pack components can be mixed/matched. Other parts that also changed are identified in the book.

I used to have an early version of adobe that would let me copy the WSM files and post them, but I no longer have that capability, sorry.

good luck, I'm sure you will find a combo of parts that will work.

Dave928S

Here's a summary I've posted previously ..... https://rennlist.com/forums/928-foru...l#post12300940

Tampa 928s

Thanks for the feedback and reminding me that keep reading the manual and don't stop at the beginning.

Spent a little more time on the WSM and measured the 78 vs 82 parts.
The 78 guide tube is 50mm and the short shaft is the newer style 56 mm seems like I have a mixed version of parts. The clutch disks are the older style so going to the new style it is 9mm longer on the rear clutch disk. With grinding off 1 mm on the guide tube as specified may allow me to install the pack but it going to be tight. With the old rear clutch disk guide tube moved all the way forward to allow for Easy installation of the assembly, seems this is not the case with newer parts.
The new 82 intermediate ring has the longer travel but should not effect the install relating to the guide tube.
Trying to wrap my head around the 1mm guide tube difference vs the 9mm longer rear clutch length. Every clutch job has allowed me to move the guide tube all the way forward with this modafacation it will barely clear the bell housing mounting location. Am I missing some thing?

Tampa 928s

Modified the guide tube buttoned everything up but disks are dragging. Adjusting the IP makes no difference there is no gap between the disks. It will not rotate by hand when turning shaft I am using the 82 setup. The only difference is that starter ring gear and the fly wheel attaches via bolts on the 78 setup and then the IP to it. The 82 set up has the starter ring gear and IP attached as an assembly.
Any ideals on what to look for, before I drop it again.

Tampa 928s

Found the problem in the process of setting up the IP plate before it gets too dark.

Optimator

Just curious: does the '82 clutch pack you installed include the throwout bearing, or are you re-using the old one?

There are opportunities for problems caused by mixing incompatible parts. The FSM attempts to address this, but much of it is (to me) incomprehensible.

Tampa 928s

The 82 pack was a complete unit only the guide tube was modified.

Link to video: https://goo.gl/photos/FNhyX71oxa4tvSnaA

Trying to adjust the intermediate plate, with clutch disengaged there is no space 1.5mm on the T adjusters. If I pull down the spring on the IP I can observe the gap. There is noting in the WSM that tells to check gap this way. The adjusters all all the way back towards the PP at the end of the travel, any feedback?
Thanks

Optimator

If I'm seeing the video correctly, at the end, after you release your prying tool from the IP spring, it looks like there is still a gap between the IP ring and the rear disc. That suggests to me that both of the discs are probably releasing properly.

Did you verify which version of the release fork you are using? This is very important. The FSM shows the different versions.