Lining Up The Clutch

[Crossrodes]

I don't have a clutch alignment tool.  A  friend told me he doesn't use one.  Instead he says he lines up the clutch by eye, loosely tightens the fasteners and then inserts the transmission spline to line it up properly.  Has anyone else used this method or are there any other little tricks that might work?

[Bob_Roller]

I have had the clutch out of my bike 6 times, and have yet to use an alignment tool .

I measure the clutch disc outer edge with the pressure plates .

Try to get it even all the way around .

After you get the transmission into place, with the input shaft up against the clutch disc splines, rotate the output shaft of the transmission to move the input shaft, it will probably 'catch' the splines, but not go on .

With the clutch release rod installed in the transmission, give the release rod a good 'bump', to release the tension on the clutch disc and pressure plates, and the transmission should go on all the way .

May not work for someone else, but hasn't failed me yet !!

[Crossrodes]

Thanks Bob.  I'll give that a try.

Mike

[Ed Miller]

I don't know if it makes any difference, but I hook up the clutch cable before torquing the tranny bolts down all the way, and activate the clutch a few times to help make sure things are lined up before I torque the tranny bolts.

I also just eyeball the clutch when installing it.  But I've only done it once.

[montmil]

The R65 Wiki hereabouts has a good photo essay on clutch replacement. Even discusses the BMW clutch alignment tool. Have you visited this page, Mike? Good tips for your job.

Monte

[Crossrodes]

Yes I saw that Monte.  Today I cleaned up a bunch of parts and tomorrow I will be using the Wiki when I put the clutch back together.

[nhmaf]

I did use the clutch alignment tool on that job - it made everything slip back together easy-peasy with no worries, but several have tol me that it can be done without out - but you may have to fuss with things a bit beforehand.   I would think that a clutch arbor tool could be easily turned out of some aluminum alloy by someone with a lathe, as well.   Apaprently there is a VW airhead clutch arbor that can also work too, if you have any friends who are VW 'airheads'...

[Crossrodes]

Unfortunately not too many Beetles left in this country (althought I still have the huge socket I used to use for wheel removal).  And I don't know anyone with a lathe (wish I had one...although I haven't used one since I was in high school).  I'll try the alignment procedures I have read here.

I'm off to see family for a week so I won't be doing anything until I return....meanwhile if I see an old VW repair shop in my travels....

[Crossrodes]

Then again..if you have a wood lathe you could make a clutch alignment tool.  Check this out: http://bobhooversblog.blogspot.com/2006/12/vw-clutch-alignment-tool.html

[Crossrodes]

Then again....for $5 you could order one of these:
http://www.germansupply.com/home/customer/product.php?productid=16834&cat=278&page=1

I just ordered one...hope it works.  I'll let everyone know.

[Crossrodes]

OK I went to use the clutch alignment tool today on my '79.  But guess what...you can't use it.  The clutch set-up on the '79 does not allow for the use of the tool.  So what I did is I set the clutch up where I thought it should be, tightened the bolts enough that the clutch would hold in place but I could move it if I needed to.  Then I loosely installed the transmission so that the splines mated and I had enough room to get a wrench on the clutch bolts.  I then tightened up the bolts tight enough that I could remove the transmission and torque the bolts.  

It worked like a charm.

[Rob Valdez 79 R65]

Both of those tools for the VW's look a lot different from mine that I bought from Ed Korn back in the '80's.  Mine only has one step, as I recall, and that is from the handle to the tool, which is the same diameter as the input shaft.  
And the tip is conical shaped, like the end of the push-rod.

I'll take a picture of it for my collection, soon.