mk1 clutch HELP!

Hi,

Im in the middle of an engine convertion on my golf.
To cut a long story short im fitting a EX scirocco AUTO engine into my golf but converting it to manual and using a mk2 020 gearbox.
After taking off the torque converter i bought a 5 piece clutch from the internet.
I have now come across a slight problem with the friction disc. The splines are a bit smaller than the ones on the gearbox.
I have had a little read into it and it turns out that the friction disc i have is 190mm and the friction disc that is needed for the 020 box should be 210mm.

Does anyone know the part number for the 210mm disc or does anyone have one they coul spare (new or used).
Also does anyone know if the 210mm will directly replace the 190mm disc with no problems or will i need to buy a new clutch kit that comes with the 210mm friction disc?

P.S. I am also after the bolts that connect the flywheel to the clutch. Does anyone know the part number for these or does anyone know where i can get these from other than VW?

Thank you for any help.

James

The size of the splines isn't related to the diameter of the friction disc. It sounds like you have a Mk1 GTI clutch, which connects to a 22mm input shaft - but you have a Mk2 16V or similar gearbox, which has a 24mm input shaft.

Find the gearbox code and look it up on the "gear ratio guide" to check.

Match the friction disc to the gearbox you're using - ie buy a clutch kit for a Mk2 Golf GTI 16V.

sorry i meant the 210mm friction disc would have a larger size spline than the 190mm one that i have.
Thank you for you help.

as above, the spline size doesnt change from 190-210, but it DOES change on mk2 16v and mk3 2.0 16v. so yes it sounds liek this is the box you have and thats why the friction disc wont fit onto it. as said, whats the box code?

if its a 16v/2.0 8v box you need a mk2 16v clutch kit, if its an 8v box you need a mk2 1.8 8v clutch kit. either way, you also need a mk2 1.8 210mm flywheel, can get it from any model but ideally use a carby flywheel as it'll have the ign timing mark in the right spot for your EX carby engine

So i will need a new flywheel?
can i not just get the friction disc to go with the gearbox?
The gearbox number is 020. its supposedly from a mk2 16V gti. think a 1.8.
Any ideas on prices for the bits?
thanks
james

020 is the type of gearbox, but there's a further subset of codes which defines the gear ratios, driveshaft fittings, mounting points ( to secure it in the car) and input shaft size. Its located on the bottom of the bellhousing, although you'll probably need to clean up the area (eg wire brush) to reveal it.

The flywheel you already have should accommodate the cluth friction disc you'll need, ie any friction disc (180, 190, 200, 210mm) will fit within the flywheel. There's probably a few exceptions for really early stuff (like pre 1977 or something) but I'd not worry about that.

the trouble is if you do have a 16v or 2.0 8v box there is no clutch kit that will fit it and a 190mm flywheel, you have no choice but to use a 210mm setup

rubjonny said

the trouble is if you do have a 16v or 2.0 8v box there is no clutch kit that will fit it and a 190mm flywheel, you have no choice but to use a 210mm setup

Are you sure there's not enough space within the flywheel?

if you have a 190mm flywheel, the 210mm friction disc im pretty certain wont fit inside it, plus the bolt holes wouldnt line up on the pressure plate. if you look at the bolt holes on the flywheel they're right at the edge so with a smaller pp they wouldnt line up?

The outer bit of the pressure plate is the same though….all flywheels are the same external size, and the flywheel bolts to the pressure plate. The inner bit of the pressure plate might be different for the 190-210mm variations, but I have a feeling its the same anyway (just the spring is stronger on a 16V item).

are you 100% sure of that? because on the MK2 1.6 they have a different flywheel inspection bung which adjusts the position of the VAG timing light tool in relation to the flywheel (1.6 one is white, 1.8 one is green)

Yes, because the starter motor engages with the teeth of the flywheel. They didn't do different positions of the starter motor (would need a slightly different casting of each gearbox) and/or different sized cogs of the starter motor gear, they were all the same just different motor power.

Whether the 1.6 Mk2 had slight differences, could be down to any other reason.

teeth on the flywheel isnt the issue though, its the rest of the dimentions which are important. you could make the flywheel any shape you like, as long as the outer lip was the same diameter for the ring gear…

other issue is the friction area in the flywheel, the 210mm one fits pretty much only round the 210mm friction material(i.e. there is no inner 'lip' for a smaller friction disc), so id assume the 190mm one would be narrower to suit

not saying i know either way, just was making sure you knew 100% they're the same is all

this is what i mean, 1.6 mk1 flywheel:
http://cgi.ebay.co.uk/Mk1-VW-Golf-GTI-1600cc-Flywheel-180mm-/320693716219

210mm flywheel:
http://cgi.ebay.co.uk/Volkswagen-Golf-MK3-Flywheel-1-9-027-105-278-D-/120685843032

note the starter toothed area, how on the mk1 flywheel there is a substantial lip between the teeth and the meat of the flywheel, and on the 210mm there isnt…

so who's right then?
Do i need another flywheel and clutch or can i just buy the friction plate that goes with the mk2 box?
Ill get the numbers off the bottom tonight though.

I am

but it depends, what box do you have? if its an 8v one you can use the right clutch to match your flywheel, job done. if its a 16v or 2.0 8v you have no choice but to buy a mk2 16v clutch and a mk1/2/scirocco/cabby 1.8 210mm flywheel

edit: or just change the box for an 8v one.  either way, let us know the codes from the flat plate on the bottom of the bellhousing, 16v is 2Y, earlyu mk1/2 8v is 9A, one of the mk3 GTI boxes is CHE, just so you know what we are looking for.

Thank you. I havent had the chance yet but i will look tonight.
We originally bought a full engine and box which was a mk2 1.8 16v. We were planning on using that but i took a A reg scirocco auto in part exchange so we decided instead of scrapping it we would use it as the donor.
We got rid of the mk2 engine but kept the box, flywheel, and a couple of other bits.
So we have the right flywheel for the box but we now obviously need the clutch for the mk2 16v and not the mk1 ex engine.
Ill have a look at the box tonight and get back to you.
Thanks

yep if the box is a 16v one you need a 210mm flywheel and a mk2 16v clutch

right o.
is the flywheel i have not the 210mm then?
or am i using the flywheel i have that came with the box and order a mk2 16v clutch?
Any ideas on part numbers for the the 16v clutch?
thanks for your help.

if you kept the fly off the 16v yarp that'll be a 210mm

3000.381.001 is the sachs part number for the 16v clutch kit, sometimes you get lucky on ebay. ECP sell them but they're expensive! GSF sell LUK clutch kit which is ok but some have reported LUK clutch failures so I prefer to use sachs.