John Speake

Glad the diagnosis is confirmed. I have heard of a couple of other Euro 16v timing rings that have slipped.

Carl Fausett

We have had mixed results with that. When we have tried we often get stress cracks just outside the weld once the weld cools. Dissimilar metals and dissimilar heat shrinkage rates. Anyway - pinning it was a better solution.

Pete L

All

Greg at Precision re positioned my ring gear and pined it instead of welding. Photos below.

I have the repaired flywheel back in the car along with the clutch. I will post some dual disk clutch R and R photos / steps for others to refer to on a S3. I also replaced ball cup.

I adjusted the dual disk intermediate plate and will do a write up on what I did with it (provided it operates correctly!). Perhaps useful in light of my disk being towards end of service lie Also did my own rebuild on the throw out bearing that Ill post the steps on

Also installed Greg Brown clutch hose - brilliant!

See Blue circles - where Greg pinned the flywheel. Said he had never seen a ring gear as loos as the one on my car



Remember to use a good quality 12 mm triple square socket!


Removing the pilot bearing after flywheel was reinstalled. Wrench in photo was used to hold flywheel in place when torquing bolts to 65 ft lbs
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jcorenman

Well done, glad to see it resolved. And +1 on the cosmic clutch hose, makes it much simpler!

zekgb

Glad you were able to get it sorted Pete, sorry I wasn't more help at Sharktoberfest (mine was the car we couldn't get a timing light reading on) but great job ruling everything else out and getting to an initially unlikely root cause.

Pete L

At Long last (yesterday), I got my clutch, exhaust system, Greg Brown clutch hose etc. assembled and attempted to start the car for first time in 6 months.

Success, it started in less than 2 seconds and ran almost perfectly. FINALLY, FINALLY FINALLY I have the major problem with this car sorted and fixed. It was a slipped timing ring gear on the flywheel as outlined above
Because I pulled the clutch to replace the flywheel, I replace the pilot bearing, throughout bearing and adjusted the intermediate plate

Here are some photos of the throughout bearing rebuilt. I was able to press out the old bearing using some PCV pipe, a vise, a 1” socket. Will also post photos of how I adjusted the intermediate plate. The clutch is operating perfectly




Tools used to press out old bearing



Inserting 1" socket to press out the cover



Pressing out the throw out bearing cover using the 1" socket, long bolt and nut and big washer



Here is the throw out bearing cover popped loose



Pulling bearing cover



Using a PVC pipe as a tool to press the bearing out of the throw out bearing body



Using the vise and PVC pipe to press out the bearing from the body



Throw out bearing loose from body



Removing old throw out bearing

Pete L

All:

Here is the reassembly of the throw out bearing using a bearing sourced form Rodger at 928Rs




Dissembled throw out bearing. New bearing to left of body with black



Inserting new bearing into the body



Using the PCV pipe as a tool to press in the bearing



Pressing in the bearing using a vise



Bearing now pressed into the body



Inserting bearing cover on the body



Pressing in the bearing cover into the body using a vise, the PVC pipe and a large socket and washer



Rebuilt throw out bearing

zekgb

That's awesome Pete. Glad you were able to get this sorted after so long!

M. Requin

Well done! Great to start the New Year with a major 928 success story.

SwayBar

Nicely done!

Mrmerlin

Happy New Year
Keep Em Flyin !

Pete L

All

Car is now pulling 18 to 19 inches of vacuum vs the 11 to 12 it was puling before and running well. Timing at idle checked with a timing light is now 10 degrees BTD vs 15 degrees ATDC with the slipped ring.

Next Steps

1. R and R all hoses due to contamination form leaking radiator oil cooler
2. R and R timing belt + new accessory belts
3. Install new tie rod ends and bellows due to split boots
4. Drain refill transaxel with redline
5. Clean injectors
6. Rear Half-shaft - repack (no slipts in boots, but original to the car)

Already Done

1. Timing ring
2. Clutch TOB and adjustment and ball cup and Gregg Brown hose
3. Fuel filter
4. TPS switch replaced
5. Top end refresh

Pete L

All

Here are steps I used to install the dual plate clutch in my 86







I moved flywheel so that the 8 mm dowel pin was facing bottom



Push the torque tube coupler back as far as possible - approximately flush with the bellhousing. This photos is from the removal but coupler is gold part to left side of intermediate shaft



Find balance marks (typically yellow dot) on the clutch disks so they can be aligned opposite of each other. I reused old disks and difficult to see the marks



Insert Throw Out bearing into arm. NOTE DO NOT INSTALL BALL CUP INTO ARM, INSTALL NEW BALL CUP ON BELL HOUSING BALL, SEE PHOTO



Place pressure plate over arm and throw out bearing. Assemble throw out bearing and washer per diagram in WSM, Note, my pressure plate had the 3 mm spacers inserted at removal - I believe a new pressure plate will come with them already furnished to ease installation



Installing large washer? on inside face of pressure plate prior to installation of clip that hold the throw out bearing to the pressure plate fingers



Ball cup on bellhousing ball. DO NOT INSTALL ON THE ARM. Be sure to grease ball cup per WSM



Grease splines of intermediate shaft (left side). Make sure to get the correct grease. Got mine form Rodger at 928Rs



Assembled pressure plate, arm and rebuilt throw out bearing



Other side of arm, pressure plate



Placed outer disk on intermediate plate as shown and added white paint marks to assure I could see that the yellow marks on the disks were aligned 180 degrees opposite of one another when viewed sideways under the car as I was holding the pack together to install it on the flywheel



Marked the flywheel as well so could assure disks were aligned with imbalance 180 degrees opposite



Place inboard disk (disk at flywheel side) (hold in place, rotate to correct orientation relative to outboard disk and insert intermediate shaft



Assembled Clutch pack

Pete L

Here are continued steps I used to install my clutch

I did not get a lot of photos as the pack is heavy and I was working alone. Couple of hints

1. Install ball cup on the bell housing ball, not in the arm!

2. Press torque tube coupler back as far as you can

3. Use clean gloves and be sure not to contaminate intermediate plate, flywheel or disks with grease

4. Use a sharpie to make marks on the flywheel and pressure plate to get the two 6 mm and one 8 mm dowel pin oriented to corresponding holes in fly wheel








Orientation of flywheel



Clutch Pack (heavy)



While under the car, carefully lift clutch pack into bell housing while maintaining the alignment of the disks. Get pack aligned with the dowel pins. Not clear in this photo, but I marked on the pressure plate where the different pins by size were located with sharpie. The intermediate shaft and its length sticking out of the pack where it goes into the pilot bearing was for me a trial and error then success exercise. I also use a punch in the 8 mm hole to help hold the pack in place

Pete L

All

I learned the hard way that the guide tube needs to have its ears inboard (towards engine). The photo below shows the guide tube correctly positioned. Was hard to take photos while manhandling the circa 30# clutch pack






Incorrect location of guide tube. ****ttttttttttttttt



Guide tube in correct location. Flywheel bots installed. Driving 6 mm dowel pins towards flywheel.



After getting pack inot correct locaton, installing 6 flywheel to pressure plate bolts, I inserterd the top of the arm onto the ball cup at the top of bell housing. Torqued flywheel bolts to flywheel



Make sure intermediate shaft is fully inserted into pilot bearing in flywheel. Moved coupler onto intermediate shaft



Coupler on the intermediate shaft



Inserting 8 mm stepped pin from engine side of flywheel



Inserted bolts to guide tube - installed clutch