quick question about clutches

[BellCityDubber]

will an 8v gasser clutch work on a 1.6td?

a friend of mine I'm helping with a 8v->16v swap has a new in box 8v clutch.... but I know the splines are different.... so being the vulture I am.. I thought I'd find out if I could use it

Anyone?

[935racer]

Yep fits just fine, all 8v water cooleds use the same splines except for the g60 which use a conventional clutch set up.

[therabbittree]

if you put a 210 mm clutch on you td you nned to swap the 200 mm fly wheel too..
deo

[BellCityDubber]

I'm bringing this back from the dead......


So, I need a clutch and I'm wondering


the AAZ 1.9 clutch is a 210mm disc right?
the typical 1.8L gasser flywheels are 200mm flywheels right?
will the 210mm AAZ disk work in the 1.8L 200MM gasser flywheel? (I know I would have to scribe a TDC mark)

now... the transmission side

I have a 91 TD with a 4S transmission

according to this:
http://www.4crawler.com/Diesel/VW_020_transmission.shtml

There are TWO types of 4S Transmissions

one has a 200mm clutch, one has a 210mm clutch
one has 90mm axle hubs, the other has 100mm axle hubs...

but neither of them specify if the 4S.... early OR late have large spline/small dowel or Small spline/large dowel off the transmission input shaft...

I suppose I can deduce if I have a 210mm flywheel if I measure my axle shafts as per broke's website

Take a piece of string and wrap it around the inner CV joint, right where it fits into the flange.... mark the string where it meets itself, so you know how far it is around the CV joint. Measure the string.

A bit over 11" (11.13) and it is a 90mm CV/flange.
Just under 12.5" (12.36) and it is a 100mm CV/flange.

So I guess my questions really are:

1. Are there really an early and late production 4S 020 Gearbox?

2. If there are differences in early and late, what are the splines?

3. If I'm running a 200mm, what flywheel substitute will work? 1.9 AAZ?

Thanks!

[lord_verminaard]

Well, I only see 90mm flanges and 200mm clutch for a 4S tranny.  But either way, I wouldn't bet that larger flanges means larger flywheel. 

The good news is, all 8v cars, gas or diesel, use the same splines on the clutch so they are all interchangeable.  MOST A3 020's used a 210 mm clutch for smoothness.  MOST earlier gas cars used a 200mm clutch, A1's mostly.  Some 16V's could have either, though most were 210, but the clutch splines on a 16v are different.  As far as I know, only the early diesels used the smallest clutch- the exception being some 4-speed cars.  ALL 16v cars had 100mm flanges.  I always thought that all other 020's were 90mm, but I could be wrong- I don't remember ever seeing a non-16v 020 with 100mm flanges that wasn't swapped.

So to answer your questions:

1.  I don't think so.
2.  See above- Spline would be the same regardless.
3.  If you have a 200mm clutch, you need a 200mm flywheel.  I'm 90% sure the AAZ flywheel is 210mm.

Clear as mud? 

Brendan

[Rabbit on Roids]

newer 8v cars had 210mm clutches. i used the clutch and slywheel off my 92 gas jetta on my 1.5 when i put it back together.