Clutch: Application and ID
Survey Of Changed Parts:
Changes On Clutch - Instructions For Replacements
- Clutch discs with symmetric liner springs and a longer hub were introduced as from December, 1980 in standard production to improve engaging behavior.
- In conjunction with this changes were also necessary on the clutch intermediate ring, central shaft I and release bearing tube.
- From 1984 models on cars have a separate test connection to check the ignition timing. This changed the dowel pin centering of the clutch in such a manner that the intermediate ring can now only be installed in correct position to the flywheel.
CROSS REFERENCE OF ORIGINAL AND CHANGED/PRESENT PARTS
Clutch Disc I (front)
- Original Version -- 928.116.011.23
Liners riveted tight on both sides with each rivet.
Without gap between liners.
Slight liner spring load: (0.0-0.4 mm)
Hub length: 20 mm
- Change/Present Version -- 928.116.011.27 or 928.116.011.33
Liners riveted alternately with only every second rivet.
Gap between liners.
Liner spring load: (0.5-0.8 mm)
Hub length: 20 mm
Clutch Disc II (rear)
- Original Version -- 928.116.011.24
Liner springs with each 2 spring plates: (0.85-1.15 mm)
Hub length: 20 mm
- Changed/Present Version -- 928.116.011.28 or 928.116.011.34
Liner springs with each 1 spring plate: (0.5-0.8 mm)
Hub length: 29 mm
NOTE: Discs with a hub length of 25 mm were used a short time. They also belong to new version.
Intermediate Ring
- Original Version -- 928.116.033.17
Travel: 0.7-1.0 mm
Label -- 3059 008 001
- Changed/Present Version -- 928.116.033.22
Travel: 1.2-1.5 mm
Label -- 3059 008 101
Since '84 models -- 928.116.033.26
NOTE: If the label is missing, the travel could be determined as follows:
- Press down clutch ring from starter ring side against stop.
- Determine gap distance on guide with a feeler gauge blade.
New version: at least 1.2 mm
Old version: at least 1.0 mm
Short Drive Shaft
- Original Version -- 928.421.235.12
Spline distance "A": 51 mm
- Changed/Present Version -- 928.421.235.13 (gray/black) or 928.421.235.16 (dull silver)
Spline distance "A": 56 mm
Guide Tube
- Original Version -- 928.116.087.11
Total length distance "X": 50 mm
- Changed/Present Version -- 928.116.087.13
Total length distance "X": 49 mm
REPLACEMENT PROCEDURES:
- Intermediate ring, central shaft and release bearing tube are no longer available in the original version.
- Clutch discs I and II are still available in original version for the diameter and dowel pin centered clutch.
- Parts of the modified/present and original version may not be installed together in one car.
- Check chart when repairing clutches with modified/present clutch parts (dowel pin centered clutch).
NOTE:
- Clutch Discs I and II, modified clutch discs (I) 928.116.011.27, and (II) 928.116.011.28, were replaced with clutch discs, 928.116.011.33 and 928.116.011.34 (different liner grade).
- Identification: color of liners.
- Clutch discs 928.116.011.27 and 928.116.011.28 will not be available after depletion of stocks.
- Clutch discs with different type liners should not be installed together in one car.
Intermediate Ring
- Beginning with 1984 models there is a separate test connection, which is connected with a TDC sensor, for checking the ignition timing. The TDC sensor signal is triggered by two cylindrical pins which are pressed in the gear ring of the clutch intermediate ring. This makes precise positioning between the intermediate ring and flywheel necessary.
- This position is guaranteed, in that one of the three centering pins in the intermediate ring has two different diameters on each end, namely 6 mm and 8 mm. A centering bore in the flywheel now has a 8 mm diameter. Consequently the intermediate ring can only be mounted in one position.
Central Shaft I
- The first version of central shaft 928.421.235.12 (no longer available) was sometimes installed together with new clutch parts.
- The modified central shaft 928.421.235.13 was replaced with central shaft 928.421.235.16 (hard nickel-plated/same size) as from June of 1983. Central shaft 928.421.235.13 will no longer be available after depletion of stocks.
- Axial movement of clutch discs on central shaft I is better after long operating time when using the hard nickel-plated version in conjunction with the specified lubricant.
^ Identification: 928.421.235.13 gray/black, 928.421.235.16 dull silver
- Lubricant specifications for splines (central shaft I and clutch discs):
^ 928.423.235.12 and 928.423.235.13 very thin coat of Optimoly HT
^ 928.423.235.16 coat of Optimoly Olista Longtime 3 EP (Part No. 000.043.024.00)
Release Bearing Sleeve
- When repairing clutch, the old release bearing sleeve 928.116.087.11 with a total length of 50 mm can be ground off to a length of 49 mm.