Hello all,

I just swapped in a AP2 engine into my 03 GPW. While I was in I installed a new SOS clutch, resurfaced AP1 flywheel, throw out bearing and pilot bearing. Got everything back together and fired up the car. Car is still up on jack stands with no wheels mounted. I bled the clutch, might still have a little air in the system as I have to push the pedal to the floor. The clutch doesn't disengage until the pedal is about 1.5" from the floor. When the car is in neutral the hubs do not spin(good right?). However, when I put the car into gear(with the engine running) the hubs start to spin but not smoothly. It acts as if the clutch is slipping badly because the hub will spin and then stutter and start to spin again. When I hit the brakes though it kills the engine instantly so the clutch is grabbing hard enough to do stall the motor. The revs climb faster than the speedometer ramps up.

I didn't wipe the surface of the fly wheel or pressure plate with anything during install. I used high temp urea grease on spline, inner thow out bearing groove, shift fork pivot point, and shift fork ball end. There aren't any strange noises coming from anywhere. I am really disgusted because of so much work put into swapping the engine and I still have a car that is up in the air.

I don't know if I should mount the wheels and drop her to the ground and see if things are different when there is resistance. Maybe the clutch needs to warm up to start biting into the flywheel. Or do I leave it in the air and take it apart again? I am almost at the point I just want to get her back on the ground and tow her to a shop. I am truly at a loss of what to do.

Any advice would be greatly appreciated.

Bill

 

Put the wheels on it and go for a drive. If it slips, then you have a real problem. The friction surfaces don't have to be absolutely spotless in order for it to grab. Make sure you don't have a rear brake dragging. I think that would cause what you're describing with the car in the air. You may need to adjust the clutch pedel free play with a new clutch. The procedure is in the service manual.

 

Ok,

I will try mounting the wheels and getting her back on terra firma and see what happens.

Bill

 

Updated for future reference since I couldn't find any reference to this problem using search.

Apparently the car needs to be on the ground for everything to work right. I assume it has something to do with the Limited Slip Differential.

First spin around the block and the SOS clutch feels great. Of course I am coming off of a stock clutch that was worn down to nothing, hell the rivets holding the clutch material to the disc were getting worn. Oh, yeah and the last time I drove my car I had a 2.0 liter engine, now I have a 2.2 liter engine.

Bill

 

Adjust free play of the pedal. I have the same thing with my SOS clutch.