Pressure plate failure

[johne]

I have a 1996 S2, one of the last ones made and have owned it from new. No mods, no chipping, no track days.

The clutch pressure plate has now failed twice in an identical way. The first time after 70,000 miles and then again after another 50,000 miles.

On both occasions, the circle of wire that runs around the heads of the diaphragm spring pivot rivets has broken. This happens suddenly as the wire snaps, the pivot point for the spring changes slightly and whilst the clutch still has “feel”, the slave cylinder now has insufficient throw to disengage the clutch so the clutch remains locked.

This engine gearbox combination has an excellent reliability record so before I replace the pressure plate for a third time, any suggestions as to what might be wrong since two identical failures can’t be random can they?

1st pressure plate was the OE fitment (Luk?) 2nd one was Sachs part no. 3082 235 134

Could something else be out of tolerance? The clevis to bulkhead on the clutch master cylinder is set to 116mm.

Any suggestions very welcome!

VIN 0022XX
Engine number ABY00XX06
6 speed gearbox CGR849XX

[ericd]

I have a 1996 S2, one of the last ones made and have owned it from new. No mods, no chipping, no track days.

The clutch pressure plate has now failed twice in an identical way. The first time after 70,000 miles and then again after another 50,000 miles.

On both occasions, the circle of wire that runs around the heads of the diaphragm spring pivot rivets has broken. This happens suddenly as the wire snaps, the pivot point for the spring changes slightly and whilst the clutch still has “feel”, the slave cylinder now has insufficient throw to disengage the clutch so the clutch remains locked.

This engine gearbox combination has an excellent reliability record so before I replace the pressure plate for a third time, any suggestions as to what might be wrong since two identical failures can’t be random can they?

1st pressure plate was the OE fitment (Luk?) 2nd one was Sachs part no. 3082 235 134

Could something else be out of tolerance? The clevis to bulkhead on the clutch master cylinder is set to 116mm.

First, I'd remove the serial numbers from the thread, you can never be too careful and you've given some useful info there...

Back to the clutch, you don't mention whether just the p/p was changed or anything else, release bearing , spiggot bearing, sl/m cylinder ?, also did you have a chance to look at the condition of any of the above including flywheel movement ?

Did you do the work yourself or at a garage/dealer both times?

My clutch went at lessthan 20k , but as you indicate the MTBF you're getting is unusual unless you're prett heavy on the clutch or drive on it which I'm sure's not the case.

[johne]

I did the work myself. First time I replaced friction plate, pressure plate, master cylinder and release bearing. Second time, i.e. now, I've the engine out and wanted to check before I put it all back together again. Flywheel appeared normal both times although it's the first time I've seen a dual mass one. Taken several performance cars to high mileages in my life on their original clutch so I don't believe it's my driving style!