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Building a 400bhp+ 2.5 ltr 944 Turbo

Interesting. I got my "cup" disc from the States a couple of years ago now (about £150 I think). I believe I have a NOS standard pressure plate (£125 from a mate who was after a KEP) and bought the thrust bearing separately for about £50. The whole lot cost under £400 including delivery on the plate from the States. This is likely adequate to 400 or so horses as Pete mentions. It's documented in my build thread I think.

Just the 4 springs on my plate David so that ties up with your info.
 
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Who is going to be fitting that for you Pete? I've always told myself that if my turbo needed a clutch, I'd pull the engine out and fit all the 3.0 bits. But unless I bought a lift, I wouldn't fancy that job now.
 
Who is going to be fitting that for you Pete? I've always told myself that if my turbo needed a clutch, I'd pull the engine out and fit all the 3.0 bits. But unless I bought a lift, I wouldn't fancy that job now.

Hi Paul

right now this is an unknown...my eldest son's ( the only person who I fully trust) business is flat-out, and it would be unfair to him to take up one of his ramps for two days to do this, that's my view, not his. I asked my local but they can't deal with something this technical, their words, not mine.. well it is a small village garage, evidently they did attempt 944 clutches in the past....:) Son No. 2 has a friend who has his own business but I don't know this guy and am not sure about using him. So a bit of a quandary right now.

Pete
 
It took me about 3 relaxed weekends during covid lockdown to replace the flywheel, with the car on jack stands. For sure it is a bit of a chore but I still regularly crawl under my cars for various jobs and I have found that the hardest part was just to decide to get going.
Despite the poor weather this may not be the most exciting occupation to fill one's spare time with in this time of the year.
 
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It took me about 6 relaxed weekends during covid lockdown to replace the flywheel, with the car on jack stands. For sure it is a bit of a chore but I still regularly crawl under my cars for various jobs and I have found that the hardest part was just to decide to get going.
Despite the poor weather this may not be the most exciting occupation to fill one's spare time with in this time of the year.
I hear what you're saying and I have considered whether I can do this job myself but to be honest my body is just not up to the task.

Pete
 
Still not too late to turn that carport into a proper garage Pete!
It's simple enough to put temporary screens around it which I plan to do anyway for the winter months. As for using it to work on the car...not I...the poor old body won't let me anymore...😥
 
Get that scissor lift bought Pete. You can invite your sons around for BBQ's, and they wouldn't be able to resist getting stuck in to the clutch job. ;)
 
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Get that scissor lift bought Pete. You can invite your sons around for BBQ's, and they wouldn't be able to resist getting stuck in to the clutch job. ;)
My son-in-law fitted one for me, but that was 20 years ago and thus he's 20 years older now...he only lives 2 miles away too...🤣🤣
 
In the meantime turn the boost down I reckon. With that super new paint job, in the words of the Fresh Prince, "You don't speed through, 2 mph so everybody sees you". :cool:
 
To answer...I only really trust my son with the car, if that means I can't drive it...so be it... 'turn the boost down'?????? Sacrilege dear sir, sacrilege...🤣🤣
 
I have been trying to work out if I do have clutch slip or something else
My main reasoning for not being convinced is the total lack pf smell from the clutch, I'm sure we are all familiar of what a failing clutch smells like.
I therefore have been testing the car trying to repeat the symptoms. Fast acceleration in 1st and 2nd is no problem, jump to third and here we get what I thought could be clutch slip but not convinced. I have found that if I hold the throttle when this happens there is zero smell and seemed to just have no power. However, back off a tiny bit and the car takes off like a scolded cat. This has led me to suspect the plugs are blowing out when the boost gets to high. A quick check of the plugs while at my son's for its MOT recently confirmed that the plugs are well past their best, or to use my son's words, these plugs are dead.

I so today I replaced them with my prefered choice of NGK Iridium IX 7's.

A few things while doing this, first when removing one of the hoses for access to No. 3 plug lead the small tube came out of the manifold, I wonder how long that's been leaking if indeed it was?
No big deal, a quick clean of tube and manifold with IPA I reassembled using a Loctite retaining bonder, in this case, 640 which is a very fast setting type.
Pictures hopefully show this.
On inspecting the old plugs they clearly are dead, well the top one from No.1 isn't too bad but 2,3 and 4 have large deposits around the probe. The good thing is that all 4 were dry and of a good colour, no sign of nasty oil.

All back together now, I'll have to leave the road test for better weather, can't test properly with wet roads.

I'll update if this solves the issue or not soon.

Pete
 

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Well took her for a test drive, at first I thought I'd solved it as she drives very well and while pushing a little hard has very high acceleration. However, if I push it then I get that clutch slipping sensation, but again, no slipping clutch smell? It's a puzzle for sure, I guess the rear main seal could be leaking and the oil is masking the smell? Not so sure on that one?
At least I have a clutch ready to go in, will ask my son to take her for a drive next time he visits, it might persuade him to do the clutch for me...🙂

Pete
 
If the RMS is leaking then that could be the cause of the slip.
Most certainly but I'd have expected at least a hint of clutch disk smell and not for the car to be fine with less throttle, less as in still hard driving, not normal driving?
 
A suggestion of a possible cause Pete...is it wheelspin???,those symptoms u describe, i have had in my red car under full boost in 3rd and 4th,car seems to stop leaping forward,back off throttle then have another go and it sticks.Cold tyres, slight bit of damp road sound right?I am running on 16 inch wheels also ,lots of boosty power coming in suddenly ....
I had slippage at quite high speed once in 4th (close to the legal limit...:whistle::rolleyes:).
Pretty sure mine slipped on the dyno also.
What do you think?
Try a couple of PSI less in the rears?See if this changes it?
 
If the clutch was slipping, wouldn't the revs would rise without an increase in speed? Same with wheelspin, what tyres have you fitted.
 
Hi guys...thanks for the input...tyres are indeed in need of changing although still gripping the road. Mark, I don't think its wheelspin as it simply doesn't feel like it, I mean I'm familiar with the tyres loosing grip but it doesn't feel right for wheelspin. There is no feedback in the car to suggest its wheelspin, however, I'm not ruling it out due to the tyres being overdue for change, plenty of tread but hardened due to age.
When testing today I came off an A road roundabout fast, no issue through 1st and second, even 3rd seemed fine until I pushed harder when the slip (if that's what it is) occured. Yes Paul, the revs shot up, now I'm no novice to either a slipping clutch or wheelspin, this just feels so different?
I spoke to my son earlier, we agreed next time he pops up he'll take her for a test drive. He doesn't think its oil from failed RMS as there's no smell of either burning oil pr burning clutch. There's also the fact that the clutch has only covered 25k miles although this is a mute point if it simply can't handle the higher torque.

If I had had any movement from the rear I'd happily go with the old tyres scenario, not ruling it out though, next time I take the car out I will try reducing the pressure in the rear tyres as you suggest Mark.

Cheers guys

Pete
 

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