Club 80-90 Forums

hello folks

I have a 1985 T25 which had a 1.6D engine until the cooling system went to pot.
so I have put in a 1Y engine, a 1.9D Seat Inca.
the gearbox is the original 4 speed.
because the original clutch was virtually new I didn't replace it.
now it's slipping under any sort of load so is this necessarily because of a slightly stronger engine
and the clutch needs to be a higher rated one? in which case what clutches fit?

thanks....

the 1.6 clutch will be fine on the 1.9

possible clutch contamination? You did put a spigot bearing in the end of the crank didn't you ?

thank you Mr Hutch!

is that the release bearing?
is it something additional that wouldn't be on the original ?!
I'm going to read the wiki .....!

All I have found is that the spigot bearing can be responsible for juddery gear changes rather than slippage.

is this bearing already present on a 1.6D / 4 speed combo, or something that needs adding when moving up to a 1.9D / 4 speed?

The spigot bearing goes inside the drive shaft on the engine - often missed, can cause problems with the gearbox seal of it's not there - search the forum? Your talking about release bearing I think


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and the lack-of/faulty spigot bearing could cause the gearbox seal to leak transmission fluid onto the clutch surface?
is that the only way the bearing can effect the clutch?

If there is no spigot bearing you will need a gearbox rebuild in the not too distant future, the input shaft needs it for support.

I don't know whether it has been left out or not as I did not do the critical bit of the install.
and as my mechanic is Spanish here in Spain, I have a hard time communicating with him about the weather let alone the tech stuff.
in any case he's saying the slippage is due to the clutch being inadequate for the 1.9 engine which I gather from the first reply above is not true!
the poster mentions the spigot bearing and I will try to tackle my mechanic about this.
but can the spigot bearing be responsible for slippage, and that by ruining the gearbox seal and leaking fluid onto the drive plate,
when the slippage occurred as soon as the engine went in, without any mileage put on.

all opinions welcome!

The 1.6 clutch should be fine, it's not so it's presumably contaminated. Will need taking apart again. The why should be fairly obvious hopefully.


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The standard 215mm clutch is good to use for AAZ and GTI conversions, so will have no problem with the lower power of the 1Y. We use it all the time on these conversions.
It sounds like incorrect assembly by your mechanic. If the box needs to come out, it's a great chance to check he put a spigot bearing in the end of the crank.

Hi , I'm driving around for the last 5 years or so
with a 1.6 clutch and a 1.9. 1y engine with no problems

Check pushrod on clutch slave. Maybe when matey has had starter off he's done something and dropped/lost/broke it and put one/something in to replace it that's a tad too long.

so with the gearbox out for the third time, the contamination is now obvious so spigot bearing it was and only a minimal amount of test driving without it did in the gearbox oil seal!
on the other side of the bell housing there is a tophat/sleeve (thrust bearing?) through which the shaft goes - it looks a bit tatty and is a very loose fit around the shaft.
does this bit need replacing as well?
I imagine not with the spigot/release bearing in place but thought I'd ask before any more gearbox removals!
cheers...

The thing you refer to is called a "Muff coupler" (yes really!). It is supposed to allow a few mm of movement in the end of the input shaft to take up any misalignment going into the engine. That's why you must have a spigot bearing, otherwise it will flail around and ruin the oil seal. If you do remove it, which can be tricky, then there are very specific instructions for adjustment, so best ask on here again.

Standard 1.6 clutch will be fine. Ours has done 30K miles on a 1.9 diesel and never slipped.

Er...I know it as an oil thrower. It has a rifled bore to direct the oil away from the seal, reducing the pressure at the shaft/seal interface, presumably to prevent leaks. If it's come loose in the casting it may need repairing. If not too bad, I've had some success in the past with JBWeld to take up the slack.

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