I am changing the clutch in my sisters jetta, it should have been done last weekend, but it didnt work out that way I took the flywheel to a local autoparts store to have it machined (an extra i got from the junkyard, that was in alot better shape than the original). When i tried to put it on it didnt fit, and i thought i might have gotten the wrong clutch kit somehow, or the flywheel didnt actually fit. After a bit of research, i was able to determine that the part numbers of both the clutch and flywheel are correct, and borrow an unmolested flywheel with the same part number, but the one i paid $80 to have it turned has a dowel pin that is way too big. I am now rather annoyed at wasting this much time because someone did a job a paid them to do incorrectly. But what should i do about it? If someone has jammed a way too big dowel pin into the flywheel that i cant ever get out, is it going to stay if he just puts the right size one in? Is it reasonable to expect a complete refund for the work, and if the flywheel isnt safe to use with the correct size dowel pin for the machinist to pay for a replacement?
Drill the hole in the pressure plate so that it fits over the larger pin.
Talk to the machine shop, don't start pointing fingers, just explain what's going on. It's possible that the junk yard flywheel came with that large pin for whatever reason.
Sometimes things like flywheels come with an oversized pin so things can only be assembled one way, the whole thing is then balanced as an assembly. Did you check all of the holes in the pressure plate?
I've also seen 'stepped' pins, the small end goes in the flywheel and the big one locates the pressure plate. That way the pin can't be driven in too far. Either way, unless the machine shop drilled the hole and installed the pin I don't see how they could be responsible.
Its a MK2 VW flywheel, so there is only one pin, and it must be removed to machine the flywheel. I am 99.99% sure that when i bought the flywheel, I was removing it for the first time since it was installed at the factory, and it had never been machined. The pin that is in it now is brand new, and it is the wrong size. I think someone just got a bigger hammer and forced it in. There is no question that the person who did the job wasted a lot of my time by performing it incorrectly. I am prepared to be polite if he is willing to fix the problem, but Im still not very happy about it.
Okay, so you got the flywhhel, removed the pin, sent them the flywheel with no pin and it came back with one that's way too big. Or you sent the flywheel with the original pin, they removed and lost it and it came back with a much larger one. Yeah, now it's his problem. It's doubtful you'll get him to pay for a replacement flywheel, I'd say just get your money back. It'll help to take the original pin with you when you go talk to them.
The second of the 2 scenarios is pretty much what happened. I got the flywheel (an untouched factory one), and took it in with the pin still in it. He took it out, machined it, and gave it back with a new pin that is too big. I borrowed another flywheel of the exact same kind so he can see what size it is supposed to be when I go show him tomorrow. If he will just give me the money back that I paid I will let it go, but I am going to politely ask for more than that at first I think, after listening to what he says he will do about it..
First, you are sure you are trying to engage the dowel with the correct hole, right? Sorry, but I had to ask. Now- the flywheel is held to the pressure plate with 6 bolts, correct? The bolts are what align and center the flywheel on VW's rather unusual design. The dowel is only there to index the flywheel in the correct spot for balance, or timing mark issues. Drill out the corresponding hole in the pressure plate so it will engage the dowel, and move on. Nine years from now, when you change the clutch again, you will have the original flywheel and your problem will dissappear.
Don't you still have the cars original flywheel? if so push that pin out put it in the new machined flywheel and be done with it.
tr8todd
New Reader
7/18/10 6:36 p.m.
Those dowel pins aren't all that important anyway. They are just there to help line up the clutch cover. The bolts take 99.999% of the force anyway. Take it out and run it camando.
ansonivan wrote:
Drill the hole in the pressure plate so that it fits over the larger pin.
Talk to the machine shop, don't start pointing fingers, just explain what's going on. It's possible that the junk yard flywheel came with that large pin for whatever reason.
This is far easier than pointing fingers. IF the pin is not too long, drill the corresponding hole oversize and get on with your life. Make a notation in the owner's manual about it so it won't be a complete surprise to the next owner, and move on.
I agree there is an easy fix, but I do think the machinist should at least be told about it. If I screwed a job up, I'd want to know about it so that I could do it right in the future.
robert
Did they drill out the hole in the flywheel to put in a larger pin? Seems like more work than finding the right pin.
Go talk to them. Worse case is you drill a larger hole in the clutch plate.
Dan
