TheSamba.com :: View topic - Clutch Job for 72 Bay Window, 2000 cc 79 engine

Sun Dec 12, 2021 8:54 am

Alright Guys, so here's a fun one for everybody. Currently in a little bit of a funky situation.
Im replacing the Clutch on my 1972 Transporter.

It has been converted over to a 2000 cc engine, so i have ordered the clutch kit for the 228mm flywheel. When i removed the engine, i noticed that the flywheel had small gouges in it running along the entire outside perimeter right next to where the starter teeth engage into the flywheel. It appears to me that the starter gear when engaged has gone past the point where it should... hmmm.

So, now i wonder... when this guy replaced the engine, did he replace the starter???
just crawled under there and here's the part number of the starter:
003 911 023A
as far as i can see beyond the overlying rust. To me seems to be the starter for the 1972 Vw 215mm flywheel... but i could be wrong not sure if anyone knows where to look up this part number?
I also believe this because my current starter does not have the pin that mounts into the bell housing. I believe the proper starter would be the SR87X.
Upon inspection of the bell housing itself...
Seems that there are four areas of the bell housing that are worn, basically at 2, 4 7 and 10 O'clock. seems to me that they are worn exactly where a larger flywheel would sit. hmm... Now ive heard of modifications being made to 1972 bell housings to adapt the 228mm flywheel (grinding away some material). Now theres a possibility that the bell housing just looks like this but it seems to me that its either from the bigger flywheel rubbing, or that it was done purposely to fit the new flywheel. Any ideas? might try to see if theres a part number on this bell housing...

Im going to take some pictures and try to add them to the thread, thanks again guys!

Sun Dec 12, 2021 9:22 am

Is it the original 002 transmission? They're not really supposed to go together, the later 091 trans that went with your 2L engine had a bigger bellhousing

Sun Dec 12, 2021 9:29 am

I also have a 1972 and am running a 2.0L. The biggest question is...what transmission are you running?

If it's the stock 1972 002, then you'll need a 210mm flywheel and clutch. That's what I am running, and it works just fine...although 210mm flywheel and clutch kits are getting pretty rare and expensive so I hope for your wallet's sake you have a 228mm in there :)

The starter 003911023A has a few different applications, I don't believe it directly indicates what flywheel you have but rather what bellhousing/trans is installed.

I'd suggest you get in there and see what part #'s you can find on the trans, and also get your best metric tape measure on that flywheel and bell housing.

Sun Dec 12, 2021 10:13 am

Part number for the engine GE 022986 (2L) 1979
Part number for transmission 002 301 103 Type 2 Transmission

When i place the 228 mm flywheel in the bell housing it fits, how do i make sure that the 91' bell housing doesnt already exist inside the vehicle?

Sun Dec 12, 2021 2:18 pm

I had to grind my 002 bellhousing like you are describing in order to fit a 2.0L and 228mm clutch into my '72

Sun Dec 12, 2021 2:20 pm

I also used the auto tranny starter don't remember the part # for it

Sun Dec 12, 2021 3:08 pm

A little more research done today... and this is what i found for part numbers and applications...

Transmission number 002 301 103 ( i believe is the 72 late bay)

Bell housing : 1972-75 Late 002 clutch housing (1.75' mounting stud length)

Starter : 003 911 023 A (Automatic transmission starter 73-79 and fits all 002 transmission bell housings. Apparently the automatic starter puts out a little more power. It also doesnt have the pinion that most bus starters have.

Im starting to believe that this bus has had the 2L motor put in it without changing out the bell housing to the 091. A miracle that my 228 mm clutch kit somehow functioned with this 002 Transmission. But it also explains why the clutch always made slight yet strange noises and finally stopped working altogether.

So now im trying to get this 2L adaptation correct to an 002 Transmission without having to do a crazy amount of changes. I had already ordered the 228mm clutch kit and flywheel... however if installing the 210mm clutch kit is an option, i can do that.

Any advice anyone?
Thanks

Mon Dec 13, 2021 3:55 pm

You are better off to use a 210mm clutch and the existing 210mm flywheel with your setup. The 228 flywheel is going to cause several issues.

Mon Dec 13, 2021 5:17 pm

current flywheel is a 228mm, however, i will get a 210mm to insure good fitting with 002 transmission and a 210mm clutch setup. time to return parts and get the right ones i suppose. Not taking any chances, running the 210mm. Should fit the 2L no problem i believe...

Mon Dec 13, 2021 7:12 pm

I have a 72 with a type4 engine

I had a 5 rib box with a 6 rib bellhousing on it and used a 2l starter & 228mm clutch

I now use a 6 rib box with a 2l starter & 228mm clutch

It was quite tight to get in for some reason

Tue Dec 14, 2021 7:21 am

Your clutch cover, disc, flywheel, and throw out bearing all must match. With your present parts on hand it would be simplest to just clearance your bell housing.

Tue Dec 14, 2021 11:54 am

i dont mind returning parts, or reselling parts. I bought everything for the 228mm kit, newly resurfaced flywheel and all..
However, i do think its best to run a 210mm flywheel and clutch kit,
i remember having issues installing the engine last time, just the fit between the clutch plate and the driveshaft pinion were awfully tight.
I also always remember strange noises coming from that area while driving. nothing alarming, but it never felt great... when i removed the flywheel i noticed gouges taken out if it from the starter overextending into it...

im assuming the PO had grinded away material in the bell housing to fit this previous clutch kit, or maybe not! or maybe it was the reason that i had damage to the clutch, a clutch that just stopped functioning, and

seeing that i have an 002 housing, isnt the safest bet to run the 210mm flywheel and clutch kit?

i dont know if changing the flywheel would change anything for the engine, like shimming..etc

Tue Dec 14, 2021 8:15 pm

You will need to check crankshaft endplay both before and after replacing the flywheel. You are also going to want to install a new Sabo flywheel seal.

Wed Dec 15, 2021 11:44 am

Quote: i do think its best to run a 210mm flywheel and clutch kit,
It may be cheaper if you already have a 210, but with a 2L motor the additional clutch surface is needed because of the greater torque the engine produces. A 210 will wear out and burn quicker.