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Clutch chatter problem

David Stroud IM Roadster DDavid Stroud IM Roadster DOttawa Canada '83 IM Soob
Lads I've got a severe clutch chatter problem when taking off in first gear. Never a chatter with the type 1 engine installed and now I've got the Soob with the Kennedy adapter. I've checked the archives and note that there can be many causes of chatter. I did change the rear seal (OEM)on the engine but there appears to be some oil coming down from that area. My bowden cable has some slack, not a full inch, but it never chattered before and I've not changed anything about it. One thing is different though and that's the current angle of the clutch lever that goes onto the throw out fork that the clutch cable attaches to. It is canted quite forward to the extent I put a 3/4" long spacer ahead of the adjusting nut. Can anyone say if that lever can go onto it's spline in more than one position? It seems like it should be more vertical but that itself wouldn't even change the rate of clutch release. I can't remember and before jumping into things I'm trying to sit back and think a bit (which is unusual of me). I did install a new, heavy duty release bearing fork and new return spring but did reuse a stock vw throw out bearing with 10,000 miles on it. The situation has gotten gradually worse over the first 300 test miles on it so to me that points to the seal. Any and all ideas welcome. Thanks.

David Stroud

 '92 IM Roadster D 2.3 L Air Cooled

Ottawa, Canada

 

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David Stroud IM Roadster DDavid Stroud IM Roadster DOttawa Canada '83 IM Soob
Lads I've got a severe clutch chatter problem when taking off in first gear. Never a chatter with the type 1 engine installed and now I've got the Soob with the Kennedy adapter. I've checked the archives and note that there can be many causes of chatter. I did change the rear seal (OEM)on the engine but there appears to be some oil coming down from that area. My bowden cable has some slack, not a full inch, but it never chattered before and I've not changed anything about it. One thing is different though and that's the current angle of the clutch lever that goes onto the throw out fork that the clutch cable attaches to. It is canted quite forward to the extent I put a 3/4" long spacer ahead of the adjusting nut. Can anyone say if that lever can go onto it's spline in more than one position? It seems like it should be more vertical but that itself wouldn't even change the rate of clutch release. I can't remember and before jumping into things I'm trying to sit back and think a bit (which is unusual of me). I did install a new, heavy duty release bearing fork and new return spring but did reuse a stock vw throw out bearing with 10,000 miles on it. The situation has gotten gradually worse over the first 300 test miles on it so to me that points to the seal. Any and all ideas welcome. Thanks.
J justinh
There's only like 4 splines on the clutch arm and shaft. It won't go on any other way. If it's canted forward and that 3/4" is all free play, your spring is broken. Adding the spacer to the cable with a broken spring is just going to burn out the throwout bearing.

That said, I think you're right, you have oil contamination in the disc causing the chatter.
David Stroud IM Roadster DDavid Stroud IM Roadster DOttawa Canada '83 IM Soob
Thanks, Justin. The spring is new, unbroken and still in place. The lever was canted forward about 25-30 degrees from vertical since the day I put the new engine in. I justified it at that point because there is a 5/8" spacer (adapter) between the new engine and the stock vw bellhousing but I overlooked the fact that the new flywheel is modified (dished at the hub) to compensate and place the clutch parts in the stock position. Therefore it doesn't explain the forward cant on the lever.
J justinh
Ah, I thought it was a recent development. About the only explanations I can think of are if those splines are not actually straight up (hard to tell from pictures if they are offset 1 tooth, the arm is normally vertical or angled slightly toward the bellhousing) the release arm was installed backwards or your crossshaft arms were welded on at the wrong angle. But assuming that your throwout bearing can move all the way back against the bellhousing when the clutch is released, the lever angle being off won't affect much.
David Stroud IM Roadster DDavid Stroud IM Roadster DOttawa Canada '83 IM Soob
Thanks for your input, Justin. Here's a bigger story. I removed a faulty Type 1 vw engine last fall and installed an EJ22 Subaru engine with a Kennedy conversion adapter plate and dished flywheel assy. which compensates for the thickness of the 5/8" adapter plate. At that time I installed a new CIP1 heavy duty "throw out fork" unit and installed a new return spring while reinstalling the existing lever arm. I do remember having a bugger of a time getting the return spring onto the lever arm. And so, with the new engine installed, I put the threaded end of the clutch cable back thru the loop of the lever arm and noticed the cable either had grown in length or the lever is too far canted forward. The cable is fine, hence my question about the correct forward cant (or not) about the correct position of the lever in the rested position. I just can't remember how it was positioned on my last VW installation. Screw it...I'll put a 24 in the garage fridge and pull the engine for a looksee on Saturday if I don't hear of any other ideas. Cheers....
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