CGT gearbox / clutch problem

[tractor Dave]

Wrong kit, Autodoc?
If it's just light scoring on the contact area, should skim fine. I just had one done local to me. Costs about £40-£50. They will need to remove those dowels. Ask nicely for them to straighten them for you. Like most things old Audi they are probably nla.

[84CoupeGT]

There are some kits listed on Autodoc but they're all out of stock. I found a couple of possibilities on other websites last night and have emailed off to try and get confirmation they'll fit.

Yes I will take the flywheel to a local machine shop to see what they can do. Interestingly (or maybe not!), I read something about the 2 dowels / roll pins, apparently they were used for early Audi dealer VAG Com diagnostics!

[Colin Aitchison]

Never seen a clutch disc with that damage, nice use of clingfilm on the gear box drive flanges, the joys of old cars.

[Colin Aitchison]

DIY Engine support bar

[84CoupeGT]

Yes, it's not what I was expecting to find, but I'm glad that at least it seems obvious now what the problem was and gives me hope that once it's all back together I may have a driveable car!

Support beam looks good. I'm definitely a fan of homemade tools where possible, but due to time and location constraints at the moment unfortunately the only option really was to buy one. I made a pressure tester for the fuel system though which was essential for diagnosing and fixing the running issues and saved me about £70!

Does anyone know about the 215mm clutch in these cars. Mine is 1984 and so I thought (looking at various parts websites) would have a 228mm clutch, but on removal it's definitely 215mm. One seller of a 215mm clutch I've found has told me the car must have been built in late 1983 despite it having an "E" (denoting 1984) in the VIN, and they think highly unlikely someone would put a smaller clutch in it at some point (which I'm pretty sure would require a different flywheel as the 228mm clutch I bought doesn't fit the flywheel on the car). Another supplier selling a 215mm clutch says it won't fit my car because it's not listed for the model (but every other 70s and early 80s Audi on their list uses the same 215mm clutch!!).

The original part numbers (friction plate 035141031T and pressure plate 035141117E) don't seem to bring up much in the way of results when searching. I would have thought though that Audi would only have had one type of 215mm clutch design with 24 splines back then, surely?!! Anyone know?

Cheers

[SwallownAmazon]

Originally Posted by 84CoupeGT

The original part numbers (friction plate 035141031T and pressure plate 035141117E) don't seem to bring up much in the way of results when searching. I would have thought though that Audi would only have had one type of 215mm clutch design with 24 splines back then, surely?!! Anyone know?

Cheers

Almost certainly correct in that assumption. Wouldn't mind betting there is a VW equivalent somewhere in their parts book; do you have a friendly independent VW/Audi specialist near you that could check for you?
Beware of fitting different clutch centre plate sizes - I once had a Vauxhall Viva GT that a previous owner had fitted a larger Ventora clutch for competiion use without doing anything to the slightly worn flywheel. This meant only the outer 15mm or so of friction material were actually in contact with the flywheel and it tore apart when I had to accelerate a bit quick to get out of someone's way.

[Colin Aitchison]

Ebay search "Audi B2 coupe clutch kit"
Item number 333745502699
look down the listing for engine numbers, it is a 215mm clutch kit

[84CoupeGT]

Originally Posted by SwallownAmazon

Almost certainly correct in that assumption. Wouldn't mind betting there is a VW equivalent somewhere in their parts book; do you have a friendly independent VW/Audi specialist near you that could check for you?
Beware of fitting different clutch centre plate sizes - I once had a Vauxhall Viva GT that a previous owner had fitted a larger Ventora clutch for competiion use without doing anything to the slightly worn flywheel. This meant only the outer 15mm or so of friction material were actually in contact with the flywheel and it tore apart when I had to accelerate a bit quick to get out of someone's way.

Good idea re: asking an independent Audi/VW specialist. I don't know any but it's worth a try to see if I can find one to ask.

I thought exactly the same about using the clutch friction plate that came with the 228mm kit I bought - only the outer 13mm would be in contact with the less worn lip on the flywheel and no doubt cause problems! Definitely won't be doing that, especially after hearing what happened with your Viva!!

I found a place to get the flywheel remachined and took it in today. It's ready to pick up tomorrow morning so I'll post up a pic when I've got it.

Also managed to get the snapped exhaust stud out of the manifold today, bought a decent stud extractor tool and after multiple dowsings in penetrating oil, hammering in all directions and several attempts it finally came out.

Also changed the rear crank seal but unfortunately I managed to wreck the new seal, the inner lip got caught up and I had no choice but to remove the seal, putting a hole in it. Another one is now on order!!

[84CoupeGT]

Originally Posted by Colin Aitchison

Ebay search "Audi B2 coupe clutch kit"
Item number 333745502699
look down the listing for engine numbers, it is a 215mm clutch kit

Funnily enough that is the exact item I contacted the seller and they are insistent it won't fit my car. I've explained everything, they said they contacted their technical department (not sure I believe them) who confirmed it won't fit!

[BackintheFold]

The "generic picture" doesn't help here does it!

They take 30 day returns-buy it, keep it spotlessly clean, if it isn't the same as yours then send it back.
Or send them photos of yours and ask them to check.

When I had a B2 90 back in the 90's, many shops told me my car didn't exist at all.

"Computer says no" mentality that will kill us all!