Clutch/starter issue

[Allen-GTR]

Guys,

I have emailed the factory with these questions, but was hoping to make some progress this weekend, so I will throw this out for help here too.

I am working on getting my clutch and starter installed this weekend, and am running into some issues. My clutch setup is a stage III SPEC (Sachs) which is the heavier duty preesure plate. The starter ring is on the pressure plate side. (looks exactly like the pictures in the build CD with the starter ring on the pressure plate.)

[pic]<a href="http://imagefort.com/hosted/a406uy70tlls4cxhbi2sawdatc35z59z.jpg">http://imagefort.com/hosted/a406uy70tlls4cxhbi2sawdatc35z59z.jpg</a>[/pic]

[pic]<a href="http://imagefort.com/hosted/djj0n17cbjybq60rqbv6ddif5mcdi8g2.jpg">http://imagefort.com/hosted/djj0n17cbjybq60rqbv6ddif5mcdi8g2.jpg</a>[/pic]

When dry fitting the pressure plate and ring gear into the transaxle along with the starter, I found that the starter gear is engaged with the ring gear right from the get-go. (without the starter being energised) I am using a Porsche starter. This does not seem quite right. The starter gear does not ride on the ring gear all the time does it?

[pic]<a href="http://imagefort.com/hosted/sqfi07cyej06vhcdg58zdldw1neje3bc.jpg">http://imagefort.com/hosted/sqfi07cyej06vhcdg58zdldw1neje3bc.jpg</a>[/pic]

[pic]<a href="http://imagefort.com/hosted/8i4cj5bwy9lqwmn824clxftce5x5hnmu.jpg">http://imagefort.com/hosted/8i4cj5bwy9lqwmn824clxftce5x5hnmu.jpg</a>[/pic]

I have not done any grinding for the starter pinion yet, as I want to make sure I am on the right track, though it looks like I will need to to allow full travel of the pinion. I am confused by the need to grind the starter bell for the pinion, since the starter is a porsche as well. When fitted to a 911, what is different? The same starter is in the same position...?

My transaxle is a 1989 G50/01. The build CD mentions the possible need to also grind the step in the bell housing down, but after reading a related post here, I believe that is for anything 1990+. I believe it was Clive that had this problem. Can anyone confirm?

[pic]<a href="http://imagefort.com/hosted/unoazbtlagov84hnxlp2d04q3dccigu3.jpg">http://imagefort.com/hosted/unoazbtlagov84hnxlp2d04q3dccigu3.jpg</a>[/pic]

Also, the pressure plate (more to the point, the release bearing) does not seem to want to slide over the guide tube in the transaxle even with moderate persuasion. I didn't want to get too ham-fisted with it. Anyone have a trick/suggestion for this? The plastic bushing (the one with the split in it) inside the release bearing seems to be holding it from seating.

I hope I have described this well enough to make sense of it!

Updated with correction... TA is a 1998 G50/01

Allen

>>> Edited by Allen-GTR on Saturday 18th September 18:48

>>> Edited by Allen-GTR on Saturday 18th September 18:51

>>> Edited by Allen-GTR on Saturday 18th September 21:47

[steve_D]

Not sure I can help with the problem yet so lets sort the pictures first.
Go to imagefort
Its free you just open an account and post your pictures. Very easy to do.
When the pictures are there each one has a link shown beside it. Highlight and copy the link. Bring it back here and paste as an embedded picture ( [pic]pasted link[/pic] )

Like this

Shout if you have problems.

Steve

>> Edited by steve_D on Saturday 18th September 18:06

>> Edited by steve_D on Saturday 18th September 18:10

>> Edited by steve_D on Saturday 18th September 18:11

>> Edited by steve_D on Saturday 18th September 18:14

[gdr]

Been a while since I put mine together, but I have the same gearbox and planned to use the Porsche starter fitted to box. Unfortunately the Porsche starter has a long pinion shaft. I believe something to do with geometry of Porsche dual mass flywheel fitted to the 964 Carrera 2 and as I recall, I had same issue with pinion engaged all the time - definitely wrong! Solution? I bought one of the hi torque starters from factory (short pinion shaft), fitted perfectly and works very well.

>> Edited by gdr on Sunday 19th September 11:46

[canam-phil]

Allen-GTR said:

Also, the pressure plate (more to the point, the release bearing) does not seem to want to slide over the guide tube in the transaxle even with moderate persuasion. I didn't want to get too ham-fisted with it. Anyone have a trick/suggestion for this? The plastic bushing (the one with the split in it) inside the release bearing seems to be holding it from seating.

There are two different diameters of guide tube. The later one is the one you want. The later release bearing does not slide over the earlier tube. Just two cross head screws hold it in place.

>> Edited by canam-phil on Sunday 19th September 10:45

[Allen-GTR]

Thanks for the information guys!

The whole transaxle/clutch/starter combination has been the most difficult part of the build. A lot of permutations to work through...

I will replace the guide tube and dig around for the correct starter.

Its hard to tell how much room I will have for the ring gear, since I am not able to seat the pressure plate on the current guide tube, but it looks like I will have enough clearance without grinding merrily away on the bell housing. (fingers crossed)

Allen

[ultimichael]

Allen,

you definitely have the wrong starter. Your´s is used
at the clutches with the ring gear on the engine side
and it needs a counter bearing in the clutch housing.
You need a starter like the IMI-101N from HiTorque.
www.goodvibesracing.com/IMI%20Performance%20Products.htm
If you are interested I can check for the number of the
original Porsche/Bosch starter you need.
As canam-phil said there are two diameters of release
bearing and guide tube.
Your guide tube probaply has 33.8 mm but you need
31.8 mm. If i`m not wrong the Porsche number is
950 116 813 06.
Hope this helps.

Michael

[gtrclive]

Yes it was me that had the Porblem etc. Just a word of warning if you use a starter in the original position on the gearbox side of the adaptor plate, then make sure it has a 10 Tooth gear and not a 9 as this promotes wear very fast due to missalignment.
And the factory stock the different bush needed for your release bearing, as stated on a nother post.

Good luck..