I'm currently deep into a clutch job on my 1987 GTI 8V. New pressure plate, release plate, disc, and remachined flywheel. While I'm at it, I'm replacing all the seals on the transaxle, as well as the pushrod bushing, release bearing, and rear main seal on the engine. Before I put everything back together, I have a couple questions for you folks:
- The end of the pushrod that contacts the release plate has developed a flat where I assume there used to be a complete radius. The release bearing side, as I guess one would expect, has much less wear. Is there a wear limit spec on the pushrod as far as flattening of the radiused ends are concerned? Is it a good idea to swap ends at every clutch job or should the pushrod always be installed in the same orientation? When does one decide the pushrod needs to be replaced? Is a new pushrod a normal part of a complete transaxle rebuild?
- I will be having the original flywheel machined for the second time. I'm sure they only remove a few thousands of material during this process, but when is it a good idea to just replace the flywheel? Is there a machining limit?
- Can someone recommend a reliable machine shop in the Seattle area that has experience machining VW flywheels?
Thanks in advance for your help.