Clutch problem..What is it with me and clutches? :-S

[Cypriotgeeza]

Ok as most of you know the clutch on my "Frankenstein" car was F**ked, and so i replaced it today...
first of all i took the box off with relative ease- due to the fact that it only had around 5 bolts holding it in.
got the box off and found the problem was that the clutch itself was extremely wide and was rubbing against the release bearing plate which in turn melted the bearing!

so the new clutch looked much thinner (bought from GSF) and i was a bit weary about it at first due to how wide the old one was.

(wanted to take pics but i forgot my camera at home and time wasnt on my side)

fitted it anyway and put it back together putting bolts in previous empty holes..
got it started and low and behold the clutch pedal only goes halfway and is then is even harder than the brake pedal had a look at the master cylinder and the pushrod which attaches onto the pedal itself was badly bent...so i replaced the master cylinder, bled the system...same problem

im thinking to now change the slave cylinder and see if it cures it but before i do i wanted to ask if anyone else has experienced this before??
any help will be GREATLY APPRECIATED!! thank you

[Rav335uk]

What box and clutch you using?

[Cypriotgeeza]

i havent got a clue rav! the box writes GETRAG on the side and i got the clutch from GSF..i think there was only one type i could buy from there

[Cypriotgeeza]

this car is a genuine frankenstein creation..so many mis matched parts its unreal

[Rav335uk]

What cars the engine from E34, did it come with the g/box too, or did you buy another?

[Cypriotgeeza]

he said it was from an E34 and the box was already attached...the clutch was finished when i bought it and i thought it just needed replacing which it did...im thinking about changing the slave cylinder tomorrow and hoping for the best

do the e34's have dual mass flywheels? because mine didnt have that?

[Cypriotgeeza]

also my clutch plate looked somethin like this because it had no springs in

http://img.diytrade.com/cdimg/796912/91 ... CLUTCH.jpg

[Rav335uk]

Looks nothing like my clutch at all.
All E34 535i's use a dual mass fly, mine does.
If yours didn't, I can only thing it's from an E28 M535i, is it a dogleg box?

[Cypriotgeeza]

how could you tell if its a dogleg? because i have never driven it before...does it write it on the box?

[Cypriotgeeza]

http://www.pelicanparts.com/BMW/catalog ... ch_kit.jpg

thats basically the exact clutch i bought!!^^

[leeparkes]

Need to know what box/clutch fly combo you got

Who done the swap? was this car brought from up my way (west mids)

[Cypriotgeeza]

was a man called "pazza" or somethin like that off here..

the flywheel was definantly a single plate and the clutch which was in it before was way too wide for it.. so im thinking maybe they knew about this problem before and tried 2 compensate for it

definantly something not right with this car

[leeparkes]

A guy came to collect 2 sets of mounts off me, one set was for his car and the other was for pazza's and i can vaguely remember him saying his mate (pazza) was using i miss match of parts

Read some of pazza's posts in the m30 section i remember he did have some gearbox problems but i think that was linkage issues

Im sure pazza did his swap in the snow


Edit: yep here it is, snow n all


http://www.e30zone.net/modules.php?name ... c&t=157633

[Rav335uk]

how could you tell if its a dogleg? because i have never driven it before...does it write it on the box?

Dogleg has 1st gear as Left and down, normally where 2nd would be.

[Cypriotgeeza]

More like he did it in the dark while it was raining .Its definantly a frankenstein creation..im just in a bad place because its on the ramp at work and my bosses are going to lose patience very quickly

Just dont know wether the flywheel is ok with the box..or if the clutch is ok with the flywheel? or if the box is even ok with the engine

thanx for that info mate

[Cypriotgeeza]

how could you tell if its a dogleg? because i have never driven it before...does it write it on the box?

Dogleg has 1st gear as Left and down, normally where 2nd would be.

The gearknob has first in the normal place if that helps..is reverse in a different place? because i dont know how else i could check where first is without driving it y'no what i mean?

[Rav335uk]

You'll know if the fly is ok it turns over ok.
Clutch looks like an E28 one.

[leeparkes]

Just edited my post with the link /\/\/\

Ill see if i can get in touch with Jay over the weekend (the guy who collected the mounts)

[Cypriotgeeza]

You'll know if the fly is ok it turns over ok.
Clutch looks like an E28 one.

true..Maybe i should try to get an E28 clutch slave cylinder and try that? really am running out of ideas

[Cypriotgeeza]

mate you are a legend for that link!! My poor car! All i have to say is they were VERY fond of cable ties..anything and everything was cable tied...even the "E-clip" which holds the gear selector onto the box was cable tied...exhaust= cabletied up

[Rav335uk]

Seriously, I hope you have used proper clips and things

[Cypriotgeeza]

im slowly and surely uncovering and rectifiying all the bodge up parts on this car Rav! i cant drive a car knowing its held together by cable ties l ol

ok so after reading the other thread i still cant figure out wether it is an E28 box or not really dont know what to do right now

[leeparkes]

When you went to GSF did you ask for a clutch for an E34 or E28

I think you might have a put a duel mass clutch to a single mass fly, i know you cant use them together but i dont know why, ive got a pic of my duel mass clutch somewhere to compare

[Cypriotgeeza]

im pretty certain ordered the E34 one...i think it was 240mm

but the thing that gets me is what the hell was in there in the first place because watever it was it was way too big! im going to take my camera in and take pics tomorrow

[leeparkes]

vague pic from the side

[leeparkes]

When you say its bigger do you mean the thickness of the cover

[Cypriotgeeza]

definantly different from mine! i dont have a dual flywheel i know that for certain..also my clutch looked like this
http://www.pelicanparts.com/BMW/catalog ... ch_kit.jpg

Just the cover itself was nearly double the size of the one i bought from GSF

[Cypriotgeeza]

189BM0160 CLUTCH KIT-240mm E34 535i 88>93 M30---that is what i bought from GSF thinking maybe i should buy this one instead

CLUTCH KIT-228mm E28 520i 81>87 108.00

but then im thinking if i have a single mass flywheel wouldnt a 228mm be to small?


Or what if i bought a dual mass flywheel..the clutch i have atm will fit..but would it work with a possible E28 gearbox?

thanx for the help guys!!

[Cypriotgeeza]

Got some pics today of my gearbox and the old clutch
(sorry for low quality, had to take them on my old k800i!)



The old clutch..the light parts are where it had been rubbing

[Cypriotgeeza]

the way the clutch plate is so rusty makes me wonder if the engine was out of the car sitting for a while without a gearbox...then maybe a gearbox was sourced which was for a different car..

thinking of everything here

[Rav335uk]

That G/box looks nothing like my E34 one

[Cypriotgeeza]

so im assuming its an E28 box? do you know anyone on here with an E28 engine or box who can confirm this please rav? im looking but cant find much

[Rav335uk]

Best to PM E21Jason, as he uses the E28 boxes in the E21's.
I've never looked at one close, but that defo is nothing like my g/box, so must be and E28 one.

[Cypriotgeeza]

Will do mate...thanx for the heads up Rav man!!

[Cypriotgeeza]

P.s did you see how mangled the clutch release bearing was?