Hallelujah the clutch is fixed.....

[wrd1972]

Finally, after 6 tranny and clutch removals, two pilot bearings, two master and slave cylinders, two pressure plates and countless headaches, foul language and money wasted the dragging clutch problem is fixed.
The clutch disk was .030 too thick and that was the reason for the fast release and difficulty getting it in gear. Amazing what .030 can do. I also found out that bleeding the clutch really isnt that hard afterall, it eventually bleeds it self, of course it had nothing to do with the problem.
I now consider myself a pro at taking LT1 clutches out, I built a transmission cradle out of 2x6 and screwed it to my hydraulic jack making the job entirely one person and almost effort free. Now I can move onto simpler to resolve problems I hope.
Thanks to all those helped out.

[Jeff_in_Atl]

Congratulations! I know how you feel about clutch problems. Been there done that.

[Gary94Formula]

Glad you got it figured out.

[Dave-S]

Why was it too thick? I never heard of anyone having that kind of an issue before......but I am glad you figured it out.

[Jeff_in_Atl]

Why was it too thick? I never heard of anyone having that kind of an issue before......but I am glad you figured it out.

The clutch disk was .030 too thick

or disc

[DJ Taso]

Congratulations! I know how you feel about clutch problems. Been there done that.

Speaking of that, has everything worked out for you, Jeff? Are you still having problems or are you finally feallin' that m6 power?

[Injuneer]

Good feedback.

How did you discover it was 0.030" too thick?

[wrd1972]

I took the OEM clutch disk to a local clutch maker and he stripped the organic linings and put on segmented kevlar linings. When all this stuff was bench clamped and tested it would release just fine, however the cars stock hydraulic system appears incapable of delivering that additional .030" of fork throw. I put a brand new organic disk in and BINGO it worked perfectly. Of course the install shop was being told that the disk was correct spec so we never really looked at it. I had finally reached the point where the only thing left was the disk so I removed it and mesured the uncompressed thickness and the kevlar disk was .348" and the stock organic was .318"
It would make sense to me that if I had an adjustable master cylinder then the disk would work fine cause then you could get that extra hydraulic power.
While the clutch was in the car it was the smoothest engagement and disengagement of a clutch I have ever driven, no chatter and clamping force out the ying yang. I really wish I could get it to work but im not spending more money to do it. I am going to ask if its possible to shim the pressure plate out .030", maybe then it will work.
I have also been told that the pull clutch setup is just very damn picky and tolerances are real close. If that the case then maybe it would work in a pusher instead. Anyway, life good again. Thanks all.

[Jeff_in_Atl]

Speaking of that, has everything worked out for you, Jeff? Are you still having problems or are you finally feallin' that m6 power?

I still haven't gotten the computer reprogrammed. PCMforless is working on it as we speak.

The difference in performance is night and day. Most is probably due to going from 2.73 to 3.42 gears. Also these cars seam to be a little sluggish below 2000 RPMs so having the clutch can keep it above the sluggish RPMs. A stall converter for the A4 car would be a big help. (Every video and my experience with F-Bodies vs Mustang is the Mustang jumps out up to about 30mph when the F-body overtakes it and starts pulling away. You can feel it in the car. It's like it takes it a second to get going. I'm wondering if the "power programming" will help this.) It's not as noticeable with the 6spd.

Since I haven't gotten my computer reprogrammed to correct the speedometer I'm not sure about the gas mileage. I read somewhere that the PPM rate of the M6 VSS was 17 and the A4 was 40. Correcting for the VSS the miles per gallon seams to have gone from ~17 mpg to ~21 mpg. It's not very often you can make your car faster and get better gas mileage. Since this is my daily driver and with the price of gas going up this is way cool. It's got me to thinking about headers.

To sum it up I am tickled to death with the conversion.

[wrd1972]

I went to see the clutch maker today and explained to him the issues with the thickness of the disks. I gave me a full refund and is going to rebuild my OEM plate so it can be sold. He verified the spec of the disk clamped but has no spec of the disk unclamped from the makers of the kevlar linings. He is also going to machine away the excess thickness and give it to me free to try if I want to down the road. I would like to put it back in cause it was unbelievably buttery smooth. Glad to see there are still people who stand behind their work.