Clutch does not release

[Dave Lagerstrom]

I finally got everything put together on my '60 cabriolet. However, the clutch would not release, that is, grinding trying to go into any gear. I believe I had the free play properly adjusted, then I tightened up the cable in an attempt to get things to work. No joy.

The engine is a super from a '62. Many years ago, we had an old Porsche racing mechanic work on the car and he put on a VW clutch. He said it was not working well and he thought it was a flywheel issue. I replaced the VW parts with new Sachs 180mm pieces (pressure plate and disc). I also get a new release bearing.

This weekend, I dropped the engine to get a look at the flywheel. The distance from the area the pressure plate mounts to the surface the disc rides on is 22.5mm. My spec book says it should be 24mm. Is this my problem? If so, can I get it machined, or should I find a replacement flywheel? Other issues I should consider?

Thanks to all for your help.

-Dave

[Vic Skirmants]

Flywheel is machined for a VW depth, but they did that only on the 200mm. If indeed your flywheel is a 180mm, time for another flywheel.

[Martin Benade]

I’m not sure if others would agree but I’d go with another flywheel for fear that it would never be in good balance again. A used flywheel with a reasonably smooth wear surface should work just fine. Just make sure to check and set the crankshaft end play.

[Dave Lagerstrom]

Thank you. I had a funny feeling that would be the case.

In the old days, I would call Jim at EASY for a used part. Any recommendation on a good place to find a used flywheel?

Cheers,
-Dave

[Timothy L Schabacker]

Perhaps Carquip in Colorado—Tom Conway. Contact is listed in the Registry vendors and services.

[Dave Erickson]

Used flywheels are a risk of getting an unusable part. Most 356 flywheels are close to EOL. I.e. they cannot be correctly machined and stay within specs. I would get an AA flywheel and avoid a used flywheel unless I had a chance to measure it and had studied the little spec book and all of its flywheel measurements.

[Martin Benade]

I would have thought most old flywheels could easily be machined and remain in spec. What part poses a problem?

[Dave Lagerstrom]

Thanks for the thoughts Dave. A little late as I already ordered a used flywheel that looks quite 'new' to my eyes. I will measure everything when it shows up and report back.

Cheers,
-Dave

[Ken Tuvman]

Dave’s a friend - I’ve seen the work he’s put into his cabriolet - he will make it right! He’s what I call an
Engineers engineer

[Dick Weiss]

I have several refinished F/wheels in my archives--180mm or 200mm.

[Dick Weiss]

Ditto in having a 912 F/wheel refinished to stage 1-specs.

[Dave Erickson]

Martin, traveling in Europe currently, I will get the little spec book out when I return.

[Harlan Halsey]

Much easier to shim the pressure plate with washers. Adjust the thickness of the shim so that the fingers of the diaphragm are nearly flat when in position with he clutch disk.

[Dave Lagerstrom]

Oh my God.

Harlan, that is brilliant. Shim the pressure plate by ~1.5 mm and it should work. I never considered it.

Now that I have a 'new' flywheel on the way, what to do?

Mind blown.

Thanks,
-Dave

[Vic Skirmants]

Much easier to shim the pressure plate with washers. Adjust the thickness of the shim so that the fingers of the diaphragm are nearly flat when in position with he clutch disk.

Did that at a race track once. Worked perfectly.