2.1 DJ thrust washer & shims

[GreatCrestedNewt]

I've just had the bearing face of my flywheel machined as it was looking a little worn. The thrust washer and shims are also in need or replacement. Can anyone please advise on availability of the thrust washer (025 105 283). VWH will have some in Jan but I'd like to get the job done before then. Any suggestions would be welcomed. Cheers.

[sandwedge]

I have one you can have its in good nick, PM me your postal address

[toomanytoys]

"bearing face"??

"Thrust washer"??

Enlighten me please
As the thrust forces should be controlled mainly by the thrust bearings on the crank in the case (case apart job) with the 3 shims taking up a small amount of residual play.. if there are not 3 then something is wrong, if they are well mullerd then something is very wrong... if the back face of the flywheel has been macjined and not the mounting face equally (or near) then you need to assemble with known shims and measure the play.. if its too big, thicker shims needed.. but you MUST use 3 to get the clearance right.., 2 will wear each other out very quickly...

[GreatCrestedNewt]

By the bearing face I mean the machined surface of the flywheel that orientates towards the retaining ring, shim and thrust washer that are positioned at the rear end of the crankshaft external to the cases. I have given the part number for the thrust washer (as listed in ETKA) in my earlier message.

I am concerned about the extent of end float on the crankshaft. The shims and thrust washer are damaged. It looks to me as though there are two possibilities - firstly, that the shim and retaining ring assembly has been assembled incorrectly previously or that there is excessive wear or movement of crank bearings or bearing races within the case.

Having had the flywheel trued, I intend to fit new thrust washer, shims and retaining ring and then check the end float. Then, if possible, adjust end float with the appropriate three shim combination. If this reveals that the end float is still excessive then I'll have to have a look inside the cases. The parts that I will have replaced up the point are required anyway and will not be damaged by assembly, so nothing lost.

I am, of course, always pleased to receive advice on how best to proceed because I am trying to work it out as I go. It would be particularly useful to have some indication of how much end float I might reasonably expect to find on the crankshaft before fitting the flywheel.

Thanks for your responses so far.

[Aidan]

I'd say the float bare should be of the order of 1mm since there will be three shim washers which are of the order f 0.24-0.34mm, the thrust washer is more than a 1mm thick iirc but not sure if that would be calculated as part of the stack height , if it is then 2mm +
I can get any of these parts you haven't been able to obtain, will be placing an order probably tomorrow, should be here later next week.
I have the seal and o ring in stock, also have a complete wbx that can be borrowed from if required.
When we did Sandwedges float the second time after the garage did it we found it was much easier with two peeps, one at the flywheel end and one at the pulley end with a pry bar, took a couple of attempts but we were happy with the measured results and afaik there's been no issues since, iirc it was a .3 and 2x .24s in his stack
I've done a couple of Vege engines where there wasn't room for even 3 .24s and they told us to just use 2 , that and other issues is why I would never get a vege (engine shop) engine in the uk, on the continent they are from the Dutch workshop I believe and have a good reputation. Simon uses them because they/GSF permit him to recharge the time he has to spend sorting them out so he can get them in, sorted and customers van out of the door rather than wait for them to sort any issues with vehicle tying up valuable space and backing up the workshop; tbfair it's a few years since I worked on any at Baxters and they may now be brilliant but then they seemed nasty, no way were they hot tested no sireee

[GreatCrestedNewt]

Thanks Aidan, I've sent you a PM. The end float I would guestimate is around 1mm.

[sandwedge]

Check the end float with the piston halfway up the bores, Aidan and I found that if the pistons were at full throw the readings were different to mid throw