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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Tue Sep 16, 2014 4:26 pm 
Somehow completely sideways in 4th

Joined: Sat Dec 24, 2005 11:21 am
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Location: a theatre somewhere
Ah, so! Verrry interesting. That's why my centerforce clutch with flat flywheel has always needed me to floor the pedal. Would be pleased to hear more about ways of making it better.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Tue Sep 16, 2014 4:31 pm 
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Joined: Mon Apr 19, 2010 4:21 pm
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Location: Saskatoon, Sk
Ugly Duck wrote:
Don't "just leave it". If you're not careful, you'll pop the slave cylinder trying to push the clutch too far.


haha, that's exactly what happened the first time I pushed the clutch in #-o

I'll try and thread out the pivot a bit and see if i can get some more throw on that TO bearing.

I'll take pics tonight.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Wed Oct 01, 2014 5:00 pm 
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Location: Saskatoon, Sk
After trying a number of things (shimming the fork, shimming the pivot, attempting to burn off a layer of clutch to make it shift) I've finally decided to throw in the towel and pull the transmission out again.

I'm fairly certain that the ford disc is too thick for the pressure plate. i'll have to measure it to be certain.

This time i plan on unbolting the bellhousing from the tranny and putting it on to test disengagement with the slave cylinder in the car. I don't want to have to remove the tranny a second time.

I fear i may also need to go with a ford Throwout bearing instead of the one i have (I checked what the new ford TO looks like at napa...mine isnt it)...there goes the easy route.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Wed Oct 01, 2014 7:28 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Jun 14, 2006 4:19 pm
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Location: Lethbridge, AB
Contact Josh at Yoshi Fab and order one of his clutch disks for the T5 conversion. I'm running one and it's fine.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Thu Oct 02, 2014 8:37 am 
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Yea, I saw that on the yoshifab website... that might be a good idea. I didn't run the serial numbers of the clutch/pressure plate before i put them back in, i just kind of assumed that they'd be fine. #-o

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Wed Oct 22, 2014 8:31 am 
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Update:

After much humming and hawing and not wanting to look at the car, i finally broke down and contacted Josh at Yoshifab about his clutch disk.

But in conversation he mentioned that they sell an appropriate TO bearing that fits the volvo fork with no modification, and has the required throw needed.

I decided to buy it and not the clutch disk, as it sounded like his T5 clutch disk has the same properties as my clutchnet one. If my clutchnet still doesnt do the job i'll buy his stuff at that time.

So, I'm going to be violating my "no tranny drop just take the engine out" rule soon.

Hopefully get the car back down before the snow flies. but unlikely.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Fri Nov 28, 2014 8:43 am 
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No progress unfortunately. However i did get the yoshifab TO bearing in the mail. But it came so late (almost 4 weeks) that I lost interest in working on it after the snow started to fly...I'd like to get to it soon so i can park my DD in there. haha

Image

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Fri Nov 28, 2014 4:51 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Location: Lethbridge, AB
Why is it welded?

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Sat Nov 29, 2014 9:05 am 
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It appears to be a spacer or retainer of some kind for the volvo fork.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Fri Jan 09, 2015 12:59 pm 
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So i got some work done over the break...

Tranny drop...actually wasn't too bad of a job. The top bolts i had to get a little creative. but it's not as bad as the AW-71 the first time i pulled it. I don't know how heavy the T5 is, but it was quite easy to handle.
Image


It became glaringly obvious why my clutch wouldn't disengage...
Image

I have the camaro tailshaft parts but the more i think about it the more i'm undecided if i should swap them out...

Image

Image

My impatient handywork...it's pretty solid tho, so oh well :roll:
The odd angles are on purpose...puts the shifter in a good place moving from 1st to 2nd gear.
Image

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Fri Jan 09, 2015 3:20 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Jun 14, 2006 4:19 pm
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Location: Lethbridge, AB
So you're not using the ripper? It's a far nicer shifter than the stock unit (I've got one in my 242). I'd use whatever tailshaft let me use the better shifter. The rest looks fine...get 'er done.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Mon Jan 12, 2015 1:01 pm 
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I decided not to change anything about the shifter and run what i've got for now. I'm more concerned with the TO bearing setup.

I removed any and all shims on the fork and ball that i had used prior to this.

With the help of a friend i bolted the transmission back on and snapped the slave cylinder back on...
Now there appears to be quite a bit of preload on the Throwout bearing...

Did some research and found out the ford TO bearings are designed to have preload...so...i guess i'll just run it for now and see what happens? Is there a way to measure "too much preload"?

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Mon Mar 30, 2015 10:24 am 
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Ok so, y'all have inspired me to try and get this to work again. I dropped the T5 yet again and took things apart.
I left my machined flat flywheel on the engine and grabbed a spare for mockup.

Image

I decided to compare my clutch setup with my "last known good" setup...OEM Sachs clutch and PP with a dog dish LH2.4 flywheel

Image

I don't know the differences between the flat and dog dish pressure plate, but i found that the clutchnet pressure plate rests on top of the clutch at almost double the height.
That would mean that i'm clamping down with a lot more force, and would require a greater release bearing pressure to disengage (just to review, I'm running the same stock hydraulic master/slave setup with a Yoshifab Throwout bearing)

Image
Image

I then measured the height of the clutch disks themselves, here is the oem sachs:
Image

And the clutchnet:
Image


So my question is: would I have to shim the pressure plate? and if so, do i shim it by:
-2.5mm (to accommodate for the pressure plate height difference)
-0.7mm (clutch height difference)

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Mon Mar 30, 2015 3:52 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Jun 14, 2006 4:19 pm
Posts: 3126
Location: Lethbridge, AB
I'm going to suggest that you contact Josh at Yoshifab and talk to him about your issues. There's an integration problem somewhere. I'm running the T5 and have had no issues with the stock TO bearing/his clutch and a centerforce pressure plate that has been handed around the club for a decade. Nothing fancy - cable operated and works fine. Not sure that shimming a pressure plate is something I'm comfortable with.

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 Post subject: Re: T5 into a 940 - Progress!
PostPosted: Mon Mar 30, 2015 6:36 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Dec 21, 2005 8:40 pm
Posts: 3482
Location: Calgary, Ab
Slipping Clutchnet clutches are rather common in the past, I'm afraid. The disc is too thick, and only once it's half worn out will it grip properly. Diaphragm clutch springs are of the over center design - have you noticed that once you press it in past a certain point, the pressure gets much lighter? Too thick a clutch disc gets it past the operating range and into the soft zone. Once the disc thins up a bit, it grabs. Obviously it messes up the geometry of the release system.


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