JX Pressure Plate vs DJ Pressure Plate

[syncropaddy]

Can anyone tell me the dimensions of a DJ clutch pressure plate? I need to know the dimension from the plate face where it contacts the disc to the face where the release bearing contacts the fingers. Thanks

[Aidan]

iirc the middle bit is pretty much the same, though damper springs are different
what are you up to ?

[syncropaddy]

Got an AAZ going into the van soon and was looking at beefing the clutch a bit. I can get the DJ disc to fit by machining out the JX flywheel but was wondering about the pressure plate.

[Aidan]

just get a tdi flywheel and machine that then you have a stronger 228mm clutch set up
Russel doesn't reckon it's required though, it's what most of the reengined syncros are running


edited to remove nonsense

[syncroandy]

Andrew I think the recipe is 1Z flywheel, machined, and VR6 coverplate/friction plate (though it might be a wbx friction plate). Not tried this myself yet but its on the cards. Aidan not sure what you say, the AAZ crankshaft issue is at the pulley end, AFIAK the 1Z flywheel bolts up fine to the AAZ crankshaft, the machining is to fit it into the bellhousing or summink.

[v-lux]

That's correct, tdi flywheel machined to match dimensions of JX.
VR6 pressure plate, 2.1WBX friction plate.

Tdi flywheel bolts straight onto AAZ crank.

Pressure plate needs a couple of tabs nibbling off of it to clear the bellhousing.

Leaves u with equivalent of a tdi clutch, but using standard td input shaft.

[syncropaddy]

Im aware of the 1Z flywheel/VR6 mod but I dont see (at the moment) why I cant machine the JX flywheel to take the DJ disc and fit a stronger pressure plate. What has the 1Z flywheel got that the JX hasn't ? Surely the DJ pressure plate will be strong enough for the AAZ. I just need to know if it will fit into the bell housing

[Aidan]

no timing marks on the dj cover plate and not sure if the dowels and bolt holes allign anyway, they use different bolts, cap heads for diesels, hex for petrol, may be different for a clearance reason or maybe different size or thread pitch ?
Never heard of anyone trying this route so don't know, only person who will know for sure is Andy Simpson and he's got better things to do now than come on here

[v-lux]

If you're going to be running a standard, unmodified AAZ then the JX clutch will be fine anyway.

Ive run a JX clutch setup for the last 3yrs with no problems. Only time it shows it's weakness is giving it grief offroad. Even then all it does is get hot and stink to high heaven.

I think the reason for using the tdi flywheel is so it matches up to the pressure plate of choice - the VR6 one being the strongest holding pressure that will fit in the bellhousing & bolt up to a readily available flywheel.

What pressure plate are you thinking of using to bolt to the JX flywheel?

[syncropaddy]

What pressure plate are you thinking of using to bolt to the JX flywheel?

Well since I was going to use a DJ disc, I though a DJ pressure plate would fit the bill as well. Just need to know if it will clear the bell housing

[v-lux]

I'm in the middle of fitting the VR6 set up right now, so had a good look at the JX flywheel yesterday in comparison with the WBX friction plate.

You would need to machine off approx 6mm to fit the WBX friction plate in there and the position of the pegs for the pressure plate means you can't quite remove enough material.

The TDI flywheel has the pegs mounted closer to the edge of the flywheel (actually mounted in the gear casting rather than the flywheel)

[syncropaddy]

So if I was to relocate the location pegs I'd be ok? What height is the VR6 pressure plate in relation to the JX one. Would it foul the bellhousing if mounted on a JX flywheel?

[v-lux]

So if I was to relocate the location pegs I'd be ok?

Hmm, not sure. It kinda looks like VW have had this thought before you hence they have put the pegs holes in a deeper gear casting. The pegs would be quite close to the edge of the fly wheel material otherwise...

Would it foul the bellhousing if mounted on a JX flywheel?

I 'think' it would fit the same, shouldn't foul....however.... wouldnt it just be easier to get a TDI fly wheel and machine that a little rather than having to mess about with the pegs?

[syncropaddy]

Getting the 1Z flywheel is the problem. I have been looking locally for quite a while now and Ive had no luck. Shipping one across from the UK is out of the question cost wise.

Having said that if anyone has a 1Z flywheel that will be in Devon maybe Dave or paul could bring it back for me as I wont be attending as I cant get away.

[syncropaddy]

Got a 1Z flywheel, pressure plate and disc, secondhand for €30, which is for nothing. Got a new VR6 pressure plate from my local VAG dealer this morning and am awaiting delivery of a DJ/DG disc. Spent a while measuring everything up and by simple machining, I reckon that a JX flywheel can be used to take a VR6 pressure plate and DJ/DG disc for the AAZ conversion. This, I hope, will be a lot easier than machining 6 or 7 lbs off a 1Z flywheel. Unfortunately, I dont have the AAZ flywheel so I dont know if that would suit machining or not.

As regards pressure plates, there is a huge choice for a 228mm DJ/DG disc. 1Z diesel, KR 1.8 petrol, 2E, ACX and 9A 2.0 petrol and the PG G60 are all the same (074 141 025B). The VR6 pressure plate is almost identical in that the final letter in its part ID number is different (074 141 025F). I will put both the 074 141 025B and the 074 141 025F into a spring rating device and test the pressure rate to see how different these two plates are. I would imagine and hope that the 074 141 025F would be the better one.

I hope to get around to all of this work during the week - it all depends if I can get a lathe free down in my mate's engineering shop to set it all up. I will take piccies along the way.