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Cone_Eater · Joined: 29 Jul 2007 Posts: 126 Location: Marshfield, MO

I have a huge problem that involves a story...
I was driving in town and there is a steep hill with a stoplight a the bottom, I am setting at this light waiting to leave and start assending the massive beast. (never had problems climbing it before) I let out the clutch and start, everything seams normal. I shift to secound, still everything seams normal, I shift to third and everything goes wrong!!!! The clutch exploded. I am not sure if this is the actual problem but it seams to fit the standards. The car made a huge pop noise and began to buc and kick. The car can roll out of gear perfectly, but when in gear it makes a horrid catch in the clutch and has a jar.
Any ideas or openions,
Thanks Sam

gohim · Joined: 02 Nov 2002 Posts: 4459 Location: Rialto, CA

Put the car up on jackstands and remove the clutch inspection plate.

If you see loose chunks of rubber, then the rubber centered clutch disk has fallen apart.

If you can't see any loose chunks of rubber, then most probably the transmission us busted.

Cone_Eater · Joined: 29 Jul 2007 Posts: 126 Location: Marshfield, MO

I removed the clutch inspection grommet and I didn't really see any pieces or rubber, but I saw a lot of dust. I wiped my finger across the fork, looked at it and the dust had a metallic glimmer.

I am thinking that the metal shavings can't be good. But I didn't see any chunks!!! Any ideas of what it could be if it wasn't the clutch? I don’t think it is the CV cause it still rolls perfect with the clutch pushed in or if it’s out of gear.
_________________
1988 924S: Koni fully adjustables, Short shift kit, head work, exhaust, K&N, Jacobs ignition, Larger Injectors, Performance Chip, 928 wheels with cooper Zeon tires, Momo interior, Etc.....
If its fast enough to go... its fast enough to blow.

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

You may want to check the CVs for rotational play. . .it might not show symptoms unless under load.
_________________
Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

Cone_Eater · Joined: 29 Jul 2007 Posts: 126 Location: Marshfield, MO

How should I do that? Also if it were the CV it would have to make that noise in the rear. It sounds to be from the front, directly after the engine.
_________________
1988 924S: Koni fully adjustables, Short shift kit, head work, exhaust, K&N, Jacobs ignition, Larger Injectors, Performance Chip, 928 wheels with cooper Zeon tires, Momo interior, Etc.....
If its fast enough to go... its fast enough to blow.

Paul · Posted: Fri Sep 07, 2007 12:51 pm Post subject:

Maybe your clutch hub has separated from the rest of the clutch disk? That would explain the metal and lack of "pieces"
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

Cone_Eater · Joined: 29 Jul 2007 Posts: 126 Location: Marshfield, MO

How do I remove the clutch inspection plate? Also where is it?

Rich H · Posted: Sat Sep 08, 2007 2:06 am Post subject:

Its on the bottom of the clutch bell housing. Its about a 6" trapizium shape with 1 bolt/screw (Wood screw in my case

) You will see the clutch cover plate and the clutch release bearing inside there.

So if its in gear and you push it what happens?

If the clutch is working you will be unable to move it as you'll be trying to turn the engine over (ie: bump/push starting it) If the clutch is not working then you will be able to move the car.
_________________
1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec

Smoothie · Posted: Sat Sep 08, 2007 2:10 am Post subject:

There's no plate, actually - all you get with the Audi 5-speed is the hole on the side that you already looked through. You'd have a larger opening at the rear if you removed the starter.
I would jack it up and place securely on jackstands and either have someone press the clutch pedal down or rig a stick to hold it down while you crawl under - then use a screwdriver through the side inspection hole and see if you can move the clutch disk up-down (that would be rotating it). If it moves easily, and a lot, then the clutch disk is ruined. Be aware that since the clutch disk, driveshaft, and transmission are all connected, there will be some play felt even with a good clutch disk due to some free-play in the transmission, so you have to discern between the feel of freeplay right there at the clutch and freeplay back at the gearbox while you're doing this. (There'll be the feeling of extra weight (inertia) of all those extra parts if everything back to the transmission is being moved.)
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Rich H · Posted: Sat Sep 08, 2007 3:39 am Post subject:

My mistake... I'll go back to '24 N/As...
_________________
1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec

Cone_Eater · Joined: 29 Jul 2007 Posts: 126 Location: Marshfield, MO

It’s the clutch!!!!

I put it in 1st and it just started rolling down the driveway.
I think this could be a problem. lol
I am about to get a SACHS clutch, Anybody use this?
What is a good rate from a mechanic for this job?
_________________
1988 924S: Koni fully adjustables, Short shift kit, head work, exhaust, K&N, Jacobs ignition, Larger Injectors, Performance Chip, 928 wheels with cooper Zeon tires, Momo interior, Etc.....
If its fast enough to go... its fast enough to blow.

Paul · Posted: Sun Sep 09, 2007 11:45 am Post subject:

8 to 12 hours labor, more if they have never seen one before...

SACHs is OEM, so yes most of us have used it.

_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

Cone_Eater · Joined: 29 Jul 2007 Posts: 126 Location: Marshfield, MO

How much power can it hold before it starts slipping? Also I have a brand new slave and master cylinder. What else should be changed while I am at it? Thanks for all the help.
Sam
_________________
1988 924S: Koni fully adjustables, Short shift kit, head work, exhaust, K&N, Jacobs ignition, Larger Injectors, Performance Chip, 928 wheels with cooper Zeon tires, Momo interior, Etc.....
If its fast enough to go... its fast enough to blow.

Cone_Eater · Joined: 29 Jul 2007 Posts: 126 Location: Marshfield, MO

I have purchased the SACHS clutch kit and it will be done in about three to five days!!! I hate to see her on a trailer.

. I got a really good rate on having it installed, $300, and it is being done by a German car specialist. He works on a lot of BMW’s and Audi’s. Is their anything I should know to correctly break it in? I planned on be gentle for about 700 miles just to make sure everything is done correctly. I will keep everyone informed as it gets finished.
_________________
1988 924S: Koni fully adjustables, Short shift kit, head work, exhaust, K&N, Jacobs ignition, Larger Injectors, Performance Chip, 928 wheels with cooper Zeon tires, Momo interior, Etc.....
If its fast enough to go... its fast enough to blow.

Rich H · Posted: Thu Sep 13, 2007 3:22 am Post subject:

I have never broken in a clutch. I've broken a couple though....

_________________
1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec