[s-cars] Clutch Rod Went Out

[Southerlin, Russell S]

Thanks for everyone's help here.  Thanks to Fred Munro for a very good
write up and some very good tips. I ended up repairing mine.  I think
the repair is stronger than OEM only time will tell.
 
Here is what I did.
The 6mm shaft is very wimpy especially if it gets any side load from
misalignments. I determine that the shaft needs to be built up to
provide more strength. That rubber isolator serves no real purpose IMO.
It may isolate some vibration from the clutch but other than that I
don't see much purpose. I'll live with a little clutch pedal vibration
if it makes it more reliable.

>From Ace Hardware I bought a couple of #1/4-20 threaded standoffs
(threaded spacers that are about 1 inch in length). I then cut the MC
shaft off at the base of the large diameter rubber piece. I then cut
some 1/4-20 threads on the MC shaft about 1 inch down the shaft. I then
J.B. Welded the spacer onto the shaft. 

Now the tricky part. The 6mm shaft will thread into the 1/4-20 spacer
but after a few threads it becomes difficult so it is almost a
interference fit - perfect. I J.B Welded a 6mmX1.0 cap screw into the
spacer and then cut the head off so I had a 6mm shaft sticking out of
the spacer.

Next I installed the clevis and adjusted the length to 109.5mm. I then
stacked up 6mm nuts and by adjusting the spacer was able to get 3 6mm
nuts to stack up against the clevis for extra strength. I think this
will provide more strength but maybe there is a weaker link somewhere
else. 

I have a picture drawn up if anyone wants a copy.

Russell Southerlin

95.5 S6



-----Original Message-----
From: Bill Mahoney [mailto:wmahoney at disk.com]
Sent: Thursday, October 28, 2004 1:46 PM
To: s-car-list at audifans.com
Cc: Southerlin, Russell S
Subject: [s-cars] Clutch Rod Went Out



Hey Russ,

FWIW HTH

http://www.audifans.com/pipermail/s-car-list/2002-September/004890.html

See if the two ends of the rod could be bolted together somehow
(coupling device or two bolts welted together perhaps.)  

 

Bill M