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EJ20T in a Kombi Clutch Problems

71EJVan - April 5th, 2008 at 04:40 PM

I have a EJ20T with a 091 gearbox (002 200mm belhousing), Kennedy Stage 2 pressure plate and stock clutch plate.

I get quite bad clutch shudder (The clutch has been adjusted where it engages 2 inches from the floor).

Any thoughts on a solution? Is it adjustment? Bowden tube (had a look at another Kombi and mine has pretty much the same curve). Bad choice of plate?

Regards
Brendan

Baja Wes - April 5th, 2008 at 07:58 PM

Where did you buy the plate, and do you remember what it looked like?

The cheap one I originally had in had an incurable shudder. See pic below, bad clutch on the left;

It eventually exploded.
I posted the following on my website after the incident;

Quote:

In the end I bought a new genuine 228mm sachs clutch plate. The difference between it and my old one is quite noticable, and after looking at the Sachs clutch it was clear it was the way to go.

The old one has 6 springs the same size, a course rough looking lining, and brass looking solid rivets (apparently only relines normally have them).

The Sachs has at least 3 different spring sizes designed to absorb various frequency vibrations and makes the driveline smoother and quieter at idle and on the move. It also has a lining of material that is finer and neater, similar in appearance to the original Mazda clutch. If looks are anything to go by, it should last heaps better than the old one ....

...When I had the old clutch in, I would get the occasional clutch shudder when using the clutch lightly, like reversing out of peoples driveways and stuff. I tried putting more bend in the bowden tube and doing the bellhousing strap up really tight, put it was always there.

With the new clutch, it's gone! No shudders, smoother take-up, more forgiving to drive. I think the different spring sizes in the Sachs clutch helps (as opposed to 6 equal springs in the other one). I also think the clutch plate itself is much more flexible. It's very nice. I'm very happy.

Are you parts new? If anything was old was it machined flat? Are the engine and tranny oil seals good? - oil on the plate can give a shudder.

Baja Wes - April 5th, 2008 at 08:04 PM

Oh, and I run a stock sachs 2L 228mm clutch plate which runs in the stock Mazda MX6 flywheel and pressure plate (which isn't heavy). This set-up gives me a normal pedal pressure and is very nice and progressive when offroading.

ElusiveStranger - April 5th, 2008 at 10:26 PM

Pleased for ya, well except for the clutch problem.

Dunno if this link will help you Brendan,
http://www.vwkd.co.uk/bb/viewtopic.php?t=1428&highlight=clutch

And a quote from Rich Jones (RJES) on another thread on there:
"I totally agree. Nobody makes a heavy duty pressure plate for a 210mm VW clutch to the best of my knowledge (I did a LOT of clutch research when developing the RJES bell housings). A heavy duty disk gives no advantage at all unless the pressure plate can provide enough clamp force to resist the torque. I'd suspect the pressure plate is standard unless they have managed to modify one from a different car, and I'd say this is unlikely, as the VW design of flywheel with the central recess for the disc is fairly unique.
I wrecked a 215mm standard clutch in my turbo Beetle with about 130 bhp years ago. Heat caused by clutch slippage took the temper out of the marcel spring between the two friction faces, resulting in on / off clutch action rather than progressive.
As rRich Baker says, at least a stage 2 KEP pressure plate will be needed with a Subaru turbo engine, maybe a stage 3. Expect a very heavy pedal!"

HTH bud

Klaus - April 6th, 2008 at 06:46 PM

I got a heavy duty pressure plate made up for 215mm (1800 kombi) clutch to go into ej20t , locally which has a 800kg (1700 lbs there abouts ) clamping pressure and have had no problems , this also uses a stock sachs friction plate . I'm up to 35000kms on conversion with no slipping or shudder just broken cv joint and stripped 3rd gear (late type 3 single side plate box 4.125 )

71EJVan - April 7th, 2008 at 01:37 PM

Wes,
Your plate on the left looks exactly like mine. I think the brand of mine was Luk. If I keep the revs down low (below 1300) get it to slip a little and walk off the clutch it is ok. Any RPMS greater and my teeth fall out. I think I'll order another plate.

Steve,
I'm using a Kennedy stage 2 but I lengthened the clutch throwout arm by 15mm to make the pedal a little softer and go easier on the cable and pedal mounting area. As you know these busses are notorious for braking cables and fracturing pedal mounting metal.

Klaus
Sounds like no substitute for quality.

Got the Blue slip and Green slip and when thi storrential rain slow up I'm going to get the plates.