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Clutch project
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Posted by Bob Davis (more from Bob Davis) on Sun, 27 Apr 2003 13:20:28 Share Post by Email
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Some of you may recall me kicking around the ups and downs of my upgraded ECU project ('95 Aero), but I'll summarize. About a year ago I installed the ECU and a 3" exhaust system, but soon realized some drawbacks to the setup.

First, exhilarating boost was typically only available when temps were below about 60°F, the lower the better, and I was experiencing unacceptable clutch slippage during full-burst acceleration in 3rd-5th gears. The analysis by most on this BB and through other sources was that the pressure plate was the weak link in the system, so I purchased a kit from Engstrom Motorsport which included a Sachs Racing PP, stock Aero disk, braided line, and t/o bearing. This weekend John Peed (alias "Quasimotor," http://www.quasimotors.com) and I took on the project of changing the aforesaid parts plus a new slave, new clutch MC, and re-surfaced flywheel. The project went well, but which completed the car exhibited a failure to disengage the clutch fully, making the car almost undrivable.

No amount of bleeding helped and the clutch pedal felt fine, so we started calling. I talked with Robert LaVergne (Zeke) and Bo Enstrom, the latter having sold me the clutch disk, PP, line, and t/o bearing. Zeke felt that we should disassemble again and check the thickness of the flywheel. It was suspected that the flywheel might have been turned too much.

At 9:30 last night we made the decision to disassemble again, and after midnight analyzed the results. The flywheel had an almost identical thickness as the stock unit, but we noticed that the PP fingers protruded very slightly more than the stock unit, which we felt might be the smoking gun. After much deliberation and meditation we decided to re-assemble with the same parts except the racing PP. The results were very satisfactory: No more disengagement problems and the slippage I experienced before is gone, at least for now. The question is, why did this PP give problems when Zeke installed an identical setup in his Aero without the woes? He did say that his pedal engaged lower to the floor, which was interesting.

Anyway, all seems well for now, even though I didn't accomplish quite what I expected. Does anyone have a clue what happened here? I'm still in a fog, partly from the questions and partly from burn-out after having pulled the tranny twice this weekend. This job is a PITA once, let alone twice in the same day.







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