Re: Welcome to my nightmare --- more on new 5ktq clutch that slips

["Lawson, Dave" <dlawson@ball.com>]

>Subsequently, I have build the following list of possible causes.
>
> - Is the flywheel not planar?  This would prevent the friction disk
>   from engaging over its entire surface and might explain the slip.
>   I don't consider this likely because the condition of the clutch
>   parts that I removed was actually quite good and I think the
>   flywheel was probably fine as well.

You are correct on this one. The flywheel is machined with a bevel
on the mating surface. The key measurements are the depth of the
face from the plane of the raised rim around the circumference. The
depth varies from inside to outside (I can't remember which is 
greater), but in order to get the correct clamping force for a given
clutch design, the depth has to be machined for it.

When I had the centerforce DF clutch built for my ur-q, with the 
similar type flywheel, the centerforce engineers told me the depth
values needed to get the correct clamping force and this information
was passed to the machinist who cut the flywheel. Both the rim and 
face get cut and flattened in order to get the correct depth.

> - Has some other lubricant found its way in there?  Nothing is
>   dripping out and I would have thought that if any contamination
>   occurred during assembly, it should have burned off by now.  Right?

Whe you were in that far, did you also change the rear crankshaft
main seal. It's a great time to do it and will eliminate oil/air leaks from
the block.

> - Was friction disk assembled facing the wrong way?  Because I was
>   quite concerned about making this mistake, I tried to be careful.
>   Also, I thought I had convinced myself that this could not happen
>   because the spring cage extends quite a bit in one direction.
>   Would this show up as a slip or as an awful racket?

That might be possible, the friction disks I have seen are always 
marked which side goes to the flywheel.


HTH
-
Dave Lawson