4drgl

Updated inserted pics of parts in question, comments appreciated

Specifically, i happened to run across an 81 5 speed that looked like it got burned n a house fire. Only sustained some interior melting and lots of paint melting... the chassis was undamaged and there was no evidence of engine fire.

So i purchased "all" of the parts necessary to convert my recent 80 car to a 5 speed, and some parts for my other 80.

I have questions on the clutch, pp, It appears to be a sachs clutch and fairly new. What is the thickness of new clutch discs and as i have not worked with a 5 speed as of yet, what r some things i should be looking for in terms of wear on the components.

As well i am aware there is a possibility the transmission "could have" limited slip if the car was a competition package. The vin tag was mutilated and i didnt bother to look for the vin on the chassis.

The # on the transmission is 901 301 101 6r...

4drgl

The best part is... only paid $220 for everything.
4 brake pad wear sensors
2 window switches
Sunroof switch
Sachs clutch
Flywheel
2 front bumper shocks
5 speed transmission
Torque tube
Transmission support
2 Rear sway bar links
Clutch master, slave, lines
Throwout bearing, fork
Brake master bottle
Brake/clutch pedal assembly.
All associated hardware, all fuses and relays.

Shoulda taken the fuse block, ac setup, air pump, may go back n get them.

4drgl

I also grabbed the starter, bellhousing, and e brake boot...

Dave928S

We'll be able to give you quicker and more accurate answers if you can post some pics of the parts, with a description of each one. It would be worth getting a workshop manual too, so we can refer you to appropriate sections and illustrations. You'll be looking for noisy throwout bearing, damaged/worn ball cup, worn fingers and plate on the PP, wear on the intermediate plate and adjusters, wear and burning on the flywheel surface, worn pilot bearing, worn discs, worn stub shaft, worn guide tube, and then going towards the back .... worn linkages, TT bearings, spline wear or damage, ... then gearbox and diff ... the list goes on.

You should methodically check everything prior to putting it in ... or you'll just be pulling it all out again.

I can post pics of quite a few new parts for comparison, along with dimensions.

Landseer

Hope the house occupants survived. Colorado has had it rough.
That said, fantastic find for you.

Ditto Hilton on everything, esp. WSM and pictures. Not a trivial swap.

Transmission number is on the very bottom of transmission transaxle webbing and is stamped in, ie, in relief. The 81 should have the factory G28-05 gearbox.

The trans number should have this format according to tech spec book: 111 XXXX

111 ---- engine type 1=8cylinder, trans type 1=5 spd, MY 1=1981
XXXX = serial number of your specific transmission
As I recall, if there is a "12" hand stamped just before serial number it has an LSD.


A way to verify is to pull the rear cover off.


You do realize that there is no place to mount the clutch master on your car, right? Folks often cut the firewall section from the donor car with a plasma cutter, then reweld it into the recieving car.

4drgl

Yes i cut the clutch master mount off the donor car as well.

I will post pics as soon as i can. Ive got a wsm and have nearly completed a restoration on one 80 auto car already. Just havent worked w a 5 speed yet.

Im pretty sure the ball and cup are worn. I noticed that. The clutch setup is quite different from the many others ive installed in other vehicles. So soon as i get to the shop ill take better pics.

4drgl

G28/05 111 1444 trans #'s

Dave928S

From the numbers it would seem you don't have an LSD .... but you can never be sure without physically checking ... and maybe someone retrofitted.

As Chris (Landseer) has already noted, it's worth pulling the rear cover off to check if you have an LSD spool, and WYAIT check for debris and clean out. This is what you'll see inside the case if you have an LSD.

Landseer

Contrasting views non lsd vs lsd

4drgl

Interesting. I will definitely pull the cover and have a look. From what i could tell of what was left of the car it was in decent shape...

but... the inspection cover was broken unsure if the idjits at the yard broke it or not... timing belt was loose and plug wires were cracked... so it wasnt in perfect shape but aside from fire damage, no major body damage no frame damage... i shoulda taken pics of the car...

The car is still kinda complete it has a sunroof, motor m28/14 engine is there, doors, door windows, interior is trash, fuseblock, front suspension less steering rack, headers r there but stock, hood, rear bumper shocks r good, theres still some good pieces if anyone is interested. Dirt cheap!! Obviously!

Hilton

Er.. that was Dave, I hadn't even read this post yet

Podguy

You need only pull the plug to see inside the differential. I use a flash light and maybe my finger to feel for the spider gears.

Here is a page about mounting the clutch master and pedals. After that it is pretty much a bolt up. Did you get the cruise control cut out switch? It mounts above the clutch pedal.

http://www.kondratyev.com/porsche/pr...ch_linkage.htm

You should pull the top over on the transmission and check the lock out, fork alignment and syncro conditions. Most older boxes need syncro work. Check also for wear on the dog teeth. Keep some oil on all your bearings.

One thing you can do is use the cruise control lock out switch in conjuction with the auto starter relay to prevent the car from starting unless the clutch pedal is depressed.

4drgl

Ha thats what i thought it was. Worked w lotsa vws so i thought it was a clutch/starter interlock. I considered going to far as to remove the proper wiring so as to wire it into my car like factory.

Yeah i thought about a flashlight. But also the coverlooks like it was leaking. As for synchros, ive rebuilt a number of automatics in fords n hondas to date.. so i considered disassembling it and checking for wear. Ive read that the early boxes get sloppy... i needa post some pics for u guys. Great info so far thx!

Dave928S

Ditto on what Dan said re taking off the top cover of the gearbox and checking inside. It's also worth changing the input shaft seal and O-ring as well WYAIT.

Podguy

The switch is a cruise control cut out switch. The wires are connected on the auto and hooked to the switch on the 5 speed. When you push in the clutch it shuts down the cruise control so the engine does not rev up during shifts.

You will have to mess with some wiring on the transmission too but that is minor.