16v conversion, gearbox help

Hi guys, does anybody know what flywheel/ clutch combination i need to sort out mating my 020 gearbox to my kr engine?? The 020 gearbox looks to be different inside the bell housing where the splined shaft is. The splined shaft has what looks like a pin which lives within the shaft and moves outwards when the clutch lever on the outside of the gearbox is operated. Where as the origional kr's gearbox (02a i think, its hydraulic clutch) has got some kind of lever with a big circle item on it which i guess pushes against the clutch pressure plate when its engaged??? please help guys if you can, im very confused…….. thanks.

Yeah, the O2A clutch/flywheel setup is completely different from the O2O.  If your KR has a o2a on it I guess it must have come from a passat/raddo or something (?), it had a O2O in the Mk2 Golf.

Basically you want the full set up to match your chosen gearbox.

Flywheel:
The Mk1 and Mk2 GTI 210mm o2o flywheels are identical so either.

Pressure plate:
Either mk1 or mk2 GTI spec.  They are interchangeable.  'Apparently' the 16v pressure plate has stonger springs, not totally convinced but if you have a choice…

Friction Plate:
To match the exact gearbox.  These are NOT interchangeable.  The Mk2 16V Golf 16V o2o friction plate has a different number of splines than the mk1 GTI o2o.

Dave

thanks for that info, does the shaft in the 020 box not have the circle like bearing part and lever set up like the o2a?? yeah, it was from a corrado 16v.

Nope it doesn't have the lever mechanism, it works differently.  The O2O The clutch cable pulls on a lever at the 'other' end of the gearbox.  That pushes the rod though and out the clutch end.

There are several 'main' parts to the o2o clutch. it (aside from bolts).
Pressure Plate (bolts to crank), then a metal disc and a metal circular clip. Then Friciton plate.  Then last of all the Flywheel which bolts over the friction plate onto the pressure plate.

ETKA image for some reason doesn't show the flywheel…


Here's a pictures of the main parts, again without flywheel:


Interesting Autotech in the states offer the clutch kit for an 8V with a 16v pressure plate:
http://www.autotech.com/prod_drive_clutch.htm

sachs clutch kits have the same prtessure plate in their 8v gti and 16v clutch kits. being a quality make I'd assume they're both 16v spec and not 8v
certainly has no issues with my 2.0 16v abf + 020 gearbox

If your pushing anything over 150hp you may want to upgrade to a performance pressure plate.   Sachs has been making their pressure plates with only one strap rathen then three.   Or,  drill out the rivots and use straps from older pressure plates.    I decided to remove my pressure plate to add straps and I'm glad I did.  all the rivots were nearly out and the holes in the straps were oval shaped.   so,  I had an extra 16v plate and I drilled out the rivots and removed the straps.  I used gauge 8 bolts on the new pressure plate to add the straps.     I only double stacked mine.   you can tripple them if ya want.

bigcaddy said

If your pushing anything over 150hp you may want to upgrade to a performance pressure plate.   Sachs has been making their pressure plates with only one strap rathen then three.   Or,  drill out the rivots and use straps from older pressure plates.    I decided to remove my pressure plate to add straps and I'm glad I did.  all the rivots were nearly out and the holes in the straps were oval shaped.   so,  I had an extra 16v plate and I drilled out the rivots and removed the straps.  I used gauge 8 bolts on the new pressure plate to add the straps.     I only double stacked mine.   you can tripple them if ya want.

I have drag raced for many years and use a datalogger to analyse clutch slip. Guess what clutch I use?

I would guess that you use a Sachs.   I don't drag race and mine was nearly apart.  and it has nothing to do with clutch slippage so it wouldn't be log'd on your data logger thing.   Maybe the suppliers there still offer the beefier pressureplates with triple straps.     Out of expierence with them,  the pressure plate straps and rivots are a HUGE weak point.   Junk.  hence the reason why they sell the performance pressure plate as well.  all about the greenbacks $$$

Just informing the original topic poster of the weaknesses of these pressure plates.  


Triple strap pressure plate shown.

The 2Y 020 gearbox has an extra spline on the main shaft - this means 8v clutches will not work with a 2Y gearbox - to get it to fit you MUST fit a 16v clutch or the 2Y main shaft will not interface.