300Tdi clutch fork failures (cont'd)

[rick130]

a couple of interesting observations re the ubiquitous clutch fork failures in Tdi's.
Most forum participants, both here and abroad recommend reinforcing behind the pivot ball to reduce the chances of the pivot ball punching through.
JC suggested to me this was a waste of time as everything else will be knackered anyway. This insight shows the value of experience as when we pulled the beast down, the slipper pivots were about to fail and one slipper had already worn through, and the diaphram was also on it's last legs, nearly worn through and finger heights all over the place.
The surface rust in the pics is because the bits were outside the workshop fro a few days i the rain 'till I cleaned up. I was lucky enough to use a neighbours concrete pit to perform the surgery, including replacing all the seals from the rear main back.
Needless to say we didn't bother firing the mig up to reinforce the cup.
We also welded a cupped washer (made by pressing a standard washer into a cup ) to retain the slave cylinder pushrod on the fork, mainly as I forgot to order a new plastic retaining clip .....

The plate itself had bugger all wear, not bad for 225,000 hard km's.

http://usera.imagecave.com/tdi-rick/grilleandclutch011-copy.jpg

http://usera.imagecave.com/tdi-rick/grilleandclutch010-copy.jpg

http://usera.imagecave.com/tdi-rick/grilleandclutch015-copy.jpg

http://usera.imagecave.com/tdi-rick/grilleandclutch017-copy.jpg

http://usera.imagecave.com/tdi-rick/grilleandclutch020-copy.jpg

http://usera.imagecave.com/tdi-rick/grilleandclutch018-copy.jpg

the 'good' slipper pad. Note the pivot hole elongation. the other one was in the bottom of the bell housing and was turfed two weeks ago. I took these pics of the bits today.

http://usera.imagecave.com/tdi-rick/grilleandclutch014-copy.jpg

[weeds]

thanks for the info rick

[sclarke]

Well there you go.....

Grommet has done 330km, no one can tell me if the clutch is orig or not...... Scary

I hate changing clutches................

[130man]

Hello Rick130, the arm in the TD5 bellhousing on my 130 is cast.Maybe they are interchangeable? I was expecting a pressed metal type but not so.My vehicle is coming together slowly but surely.Cheers, 130man.

[rangieman]

Hello Rick130, the arm in the TD5 bellhousing on my 130 is cast.Maybe they are interchangeable? I was expecting a pressed metal type but not so.My vehicle is coming together slowly but surely.Cheers, 130man.
Now thats good news after what you have just been thru:cool: