V8 Models: What Flywheel And Clutch Combo Are You Running?

[Nollywood]

Hello guys!

I've decided to start this thread, due to different options when running either a factory manual, or converting the ZF5HP19/24A to manual.

Some folk run their chosen flywheel and clutch set-up in conjunction with an engine-to-transmission spacer, either from the B5 S4, or the slightly thinner one from the B7. Now, there's no spacer option listed for the C5 or D2 V8, when running an 01E 6-speed manual. I'm running a genuine Audi S8 D2 flywheel, with matching friction disc and pressure plate. Stack height is 85,0mm. Now I've had no contact between the clutch pressure plate and 01E tranny, when bolted to the engine. No spacer fitted.

Why do some users experience clutch pressure plate-to-tranny contact, resulting in the need of a spacer? Is it down to what flywheel and clutch you choose? Please post your set-up, include stack height, if possible with a picture. My combo is shown below:

[Nollywood]

C'mon, guys! There must be a whole bunch of V8 owners here, that have pulled their manual trans to replace a clutch, or converted their tip to manual?

[Audimuscle]

I have JHM LWFW, B7 RS4 PP with JHM Stage 4 Clutch. I tried with the stock flywheel but it was to thick so I just went with the LWFW to avoid having to shave the flywheel. There is a member here that did the resizing on the stock flywheel his nick is a6v8 i beleive.

sorry I donn't have any measurements

[Nollywood]

^^^ I see. So I take it the JHM clutch is taller than the stock C5 item?

[Scotty@Advanced]

Hello guys!

I've decided to start this thread, due to different options when running either a factory manual, or converting the ZF5HP19/24A to manual.

Some folk run their chosen flywheel and clutch set-up in conjunction with an engine-to-transmission spacer, either from the B5 S4, or the slightly thinner one from the B7. Now, there's no spacer option listed for the C5 or D2 V8, when running an 01E 6-speed manual. I'm running a genuine Audi S8 D2 flywheel, with matching friction disc and pressure plate. Stack height is 85,0mm. Now I've had no contact between the clutch pressure plate and 01E tranny, when bolted to the engine. No spacer fitted.

Why do some users experience clutch pressure plate-to-tranny contact, resulting in the need of a spacer? Is it down to what flywheel and clutch you choose? Please post your set-up, include stack height, if possible with a picture. My combo is shown below:

I looked into using the B6/B7 flywheel and the starter ring gear is larger by several teeth. It may be possible to use the flywheel with a B5/C5 ring gear but I didn't go that far.

Many use the B5 setup with the spacer with good results. I've done this route as well as went the Euro S6 route with a European S6/S8 flywheel, you don't need the spacer for that option, but the flywheel is pretty expensive.

[Nollywood]

I looked into using the B6/B7 flywheel and the starter ring gear is larger by several teeth. It may be possible to use the flywheel with a B5/C5 ring gear but I didn't go that far.

Many use the B5 setup with the spacer with good results. I've done this route as well as went the Euro S6 route with a European S6/S8 flywheel, you don't need the spacer for that option, but the flywheel is pretty expensive.

That's interesting, I've never looked at the B6/7 flywheel option. This OEM S8 flywheel cost me $326, so was a pretty good deal, considering it had to come from Germany. It's single-mass too, which made it even more appealing.

[Scotty@Advanced]

That's interesting, I've never looked at the B6/7 flywheel option. This OEM S8 flywheel cost me $326, so was a pretty good deal, considering it had to come from Germany. It's single-mass too, which made it even more appealing.

Lucky you, My cost is ~350 Euro before shipping.

[alterdcreations]

I used a s4 aluminum flywheel and a stock a6 2.7 clutch. After break in, it holds fullpower I have a spec stage 3+ waiting for transplant

[demon_s8]

Hey, I'm hoping someone in this group can help me in this forum. I'm in the middle of doing the b5 v8 conversion. But it won't start. I'm wondering if you guys can help me out. When utilizing the dual mass flywheel, do you remember if all bolts lined up? When I have the engine set at TDC and try and have the home position on the flywheel at the CPS, all the bolts don't go in.

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[julex]

Well, what do you consider "home position"?

[demon_s8]

Well, what do you consider "home position"?

I'm utilizing the 30v dual mass flywheel. The home position is the double blank space on the trigger wheel portion of flywheel. Did you use a similar set up on your swap?





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[rollerton]

Pretty sure people have used that flywheel before-- but FWIW I think there was a thread where it was found that the trigger wheel was not oriented right on a couple different flywheels, compared to where the CPS goes on the trans.
Last year there was a discussion that showed some flywheels (Fidanza for one?) could be positioned a couple different ways on the crank. I'd be surprised if that was possible with an OEM unit. But..I guess if you want to use that FW you have to find out how the holes line up and decide if the CPS position matches up.

p.s. I'm doing my clutch again soon- if someone recently has used the stock A6 clutch (non Rs4) on a V8 and had it NOT slip that would be great news. I'm done with the Rs4 setup, too stiff.

[Scotty@Advanced]

Pretty sure people have used that flywheel before-- but FWIW I think there was a thread where it was found that the trigger wheel was not oriented right on a couple different flywheels, compared to where the CPS goes on the trans.
Last year there was a discussion that showed some flywheels (Fidanza for one?) could be positioned a couple different ways on the crank. I'd be surprised if that was possible with an OEM unit. But..I guess if you want to use that FW you have to find out how the holes line up and decide if the CPS position matches up.

p.s. I'm doing my clutch again soon- if someone recently has used the stock A6 clutch (non Rs4) on a V8 and had it NOT slip that would be great news. I'm done with the Rs4 setup, too stiff.

For an S6? I wouldn't use it, several of my swap customers who have used the stock S4 clutch reported slipping at WOT after break in.

[rollerton]

For an S6? I wouldn't use it, several of my swap customers who have used the stock S4 clutch reported slipping at WOT after break in.

I was actually going to call you, Scotty. So..not to thead-jack....but...what are my options then with an OEM DMFW? Rs4 or nothing?

[SteveKen]

For the NA 4.2, I say you can't go wrong with the stock DMFW (with lip machined off of the rear face where it would otherwise hit the rear main seal cover) and the stock B5 RS4 clutch ans pressure plate.

[Ko4S4WI]

For the NA 4.2, I say you can't go wrong with the stock DMFW (with lip machined off of the rear face where it would otherwise hit the rear main seal cover) and the stock B5 RS4 clutch ans pressure plate.

Also, there is a "spacer" so you do not have to have the flywheel machined.

[demon_s8]

I have in the spacer between the crank and flywheel , learned that the hard way the first time.... my whole issue is the car won't start..... so, I asked a tech at the dealer who incorrectly advised me that the home position on the flywheel needs to be at the CPS @ TDC. Totally incorrect . At that setting only 6 of 8 bolts are able to go into crank shaft.


The timing is spot on yet the car backfires into intake and floods, everytime. I get spark and fuel. I used the bar to lock cam gears, locking pin at crank and marks align @ the intake cams as well, compression is 190 across and it still won't start.

Immo defeat done by dillinger and the engine came out of a vehicle that ran and drove ....

I'M ABOUT TO USE A GAS AND MATCH!!!!

Any help gladly appreciated.

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[rollerton]

You just need to verify that you're looking at the crank trigger spot and TDC the right way and double check which flywheel you're using. I'd guess there are half a dozen V6 flywheels that might physically bolt on, but be from a variety of engines where the CPS was in a different place in the trans- like FWD cars or a VW or something. I'm just guessing, but there are a few ways it could be mis-matched.
I mean- you're putting a V8 in an A4? Is the A4 quattro or FWD?
And what car specifically did that flywheel come from?
What I'd do is research where the STOCK S8 (would be a TC/ flex plate combo in the U.S.) crank trigger sits when on TDC and compare to what you end up with that flywheel. From what I've seen most people in the C5 world use either the A6 (S4) DMFW or an aftermarket SMFW. Though I've read the 2.8 V6 flywheel can be used- clutch setup just isn't as available to hold power.

[demon_s8]

You just need to verify that you're looking at the crank trigger spot and TDC the right way and double check which flywheel you're using. I'd guess there are half a dozen V6 flywheels that might physically bolt on, but be from a variety of engines where the CPS was in a different place in the trans- like FWD cars or a VW or something. I'm just guessing, but there are a few ways it could be mis-matched.
I mean- you're putting a V8 in an A4? Is the A4 quattro or FWD?
And what car specifically did that flywheel come from?
What I'd do is research where the STOCK S8 (would be a TC/ flex plate combo in the U.S.) crank trigger sits when on TDC and compare to what you end up with that flywheel. From what I've seen most people in the C5 world use either the A6 (S4) DMFW or an aftermarket SMFW. Though I've read the 2.8 V6 flywheel can be used- clutch setup just isn't as available to hold power.

I went with what I thought was the easiest route .I specifically looked for the 2.8 v6 quattro(2001) because in all the forum's, it is said to be the best platform for conversion. I actually pretty much mimicked Bhusted with his conversion, so I'm certain that the flywheel (dual mass) can work. I went as far as to check a spare flywheel from a 1998 and all marking points match. Unless audi has more than one DMF???? For that year

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[demon_s8]

Is anyone on this chat who has done the b5v8 swap in the tri state area? If so I would like to see if my computer is able to start another vehicle. If not, it's a strong probability that I purchased a faulty ecu from the junk yard.

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[Scotty@Advanced]

Though I've read the 2.8 V6 flywheel can be used- clutch setup just isn't as available to hold power.

Stock 2.8 clutch is enough for a bone stock (not S) V8, and southbend makes a beefed up version that is 600 ft/lbs if you need that much clutch.

[Jsol]

Stock 2.8 clutch is enough for a bone stock (not S) V8, and southbend makes a beefed up version that is 600 ft/lbs if you need that much clutch.

Does the southbend 600ft/lbs work with the dual mass 2.8 flywheel?

[Niebelheim]

Just a quick info for those interested (maybe mainly Europeans) I bought my flywheel from TTV Racing. They make single mass flywheels, and they have for both 8- and 10-bolt cranks. The flywheel is based on a 2.7t flywheel, but is made 11mm thinner, so you don't need the spacer between the engine and gearbox. Fits with a B5 S4 clutch. Worked perfectly on my 00 S6. The price is £360 included shipping to Norway.

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[Jsol]

I was just about to purchase a TTV flywheel for the 4.2 turbo I am building but was worried the stock B5 RS4 clutch wouldn't handle the torque. I already have a Tilton cerametallic twin plate clutch and flywheel setup for an I5 . After comparing it to the 40v V8 auto flywheel they are very similar. The starter ring is the same and looks like I just need to turn down the I5 flywheel around the outside to the proper height to install the tone ring in the correct position. I can't post photos as I don't have enough posts I think.

[Nollywood]

Jsol, I would advise you use a V8 flywheel.

It's best to go with what has been constantly proven to work, as opposed to using non-matched parts, just because you've got them lying around.

[Jsol]

The 7A flywheel will work with some modification, but I think I will just buy the TTV F/W and OEM Sachs B5 RS4 clutch kit as I just can't find the time or space to get my B3 into the shed to remove the engine etc to use the flywheel.

[Scotty@Advanced]

The 7A flywheel will work with some modification, but I think I will just buy the TTV F/W and OEM Sachs B5 RS4 clutch kit as I just can't find the time or space to get my B3 into the shed to remove the engine etc to use the flywheel.

7A flywheel does not have the teeth for the crank sensor.

[Jsol]

7A flywheel does not have the teeth for the crank sensor.

Yes that's right. I was going to turn the flywheel down on the lathe and use the tone ring off the V8 flex plate.

[Jeremyboukaia]

Ok guys need some help! 2001 Audi a8l 4.2l 40v swapped 6speed. Is my clutch correct or will I have problems? I have a 2004 all road 2.7t clutch and flywheel with spacer bolted to my 01E tranny. I haven't started the car yet but I feel like my clutch pedal dosnt have the right feel to it?.


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[swamper8]

Ok guys need some help! 2001 Audi a8l 4.2l 40v swapped 6speed. Is my clutch correct or will I have problems? I have a 2004 all road 2.7t clutch and flywheel with spacer bolted to my 01E tranny. I haven't started the car yet but I feel like my clutch pedal dosnt have the right feel to it?.


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What's the thickness of your spacer? The Allroad used two different thickness spacers depending on if there was a automatic trans or a manual trans. I own both. I can measure them when I get home. When I had a 4.2L BAS motor in my Allroad with 01E trans I wound up using the auto trans spacer.
As stated earlier in this thread, if you used a stock 2.7T DMFW, you would have had to use a shim or spacer between the flywheel and the crank. Did that get put in there? I'm not sure what happens if you don't use it; either rubbing on the block or perhaps some issue with the starter.

[swamper8]

Just a quick info for those interested (maybe mainly Europeans) I bought my flywheel from TTV Racing. They make single mass flywheels, and they have for both 8- and 10-bolt cranks. The flywheel is based on a 2.7t flywheel, but is made 11mm thinner, so you don't need the spacer between the engine and gearbox. Fits with a B5 S4 clutch. Worked perfectly on my 00 S6. The price is £360 included shipping to Norway.

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What TTV PN did you purchase? The only one I see on their website that is as you describe (4.2L V8, no spacer, use B5S4 clutch) is PN 3580. However the descriptions says "Description: Audi 4.2 32v V8 to O1E" where as I think your motor (and my motor as well) are 40V 4.2's. Is this the one you purchased or did you get something different?
http://ttvracing.com/products/?manuf...type=flywheels

[Niebelheim]

What TTV PN did you purchase? The only one I see on their website that is as you describe (4.2L V8, no spacer, use B5S4 clutch) is PN 3580. However the descriptions says "Description: Audi 4.2 32v V8 to O1E" where as I think your motor (and my motor as well) are 40V 4.2's. Is this the one you purchased or did you get something different?
http://ttvracing.com/products/?manuf...type=flywheels

No, the one I bought is PN 0883
It says 32v on it, but it still fit. I'm guessing the crankshaft is the same on 32v and 40v with 8-bolts?
http://ttvracing.com/product/audi-v8...ufacturer=audi

[swamper8]

oh I'm sorry, I put down the PN for the 10 bolt version. So you bought 0883. So per your post, your 01E is bolted directly to your engine block? And the flywheel is bolted directly to the crank? What did you use for a starter? Stock S8?

[Niebelheim]

oh I'm sorry, I put down the PN for the 10 bolt version. So you bought 0883. So per your post, your 01E is bolted directly to your engine block? And the flywheel is bolted directly to the crank? What did you use for a starter? Stock S8?

Yes, no spacers needed anywhere. I used my stock S6 Starter, so I assume the stock S8 Starter will also work. Been driving the car daily for 7 months now, and not a single problem.

[rollerton]

Here's the Flywheel I bought from SRM--> SRM ttv-flywheel <--. Talked to them yesterday because I never got an order receipt / confirmation and they told me he literally had JUST 5 minutes earlier opened the new shipment from TTV and had a couple B7 flywheels to fill orders.
I used their order form and just slected "clutch type B7" . It's in the mail, he said I should have it Friday. AFAIK you still need the bellhousing spacer with just about every flywheel except the 2.8 ones? Do not need the shim behind the flywheel though. It shouldn't be confusing, any 2.7 application flywheel bolts right on, 8 bolt crank. I skipped the V8 application parts since the V6 ones are what everyone uses. If you Start trying to read TOO much detailed info from different sources then it's not so easy to understand.

[Niebelheim]

Here's the Flywheel I bought from SRM--> SRM ttv-flywheel <--. Talked to them yesterday because I never got an order receipt / confirmation and they told me he literally had JUST 5 minutes earlier opened the new shipment from TTV and had a couple B7 flywheels to fill orders.
I used their order form and just slected "clutch type B7" . It's in the mail, he said I should have it friday. AFAIK you still need the bellhousing spacer with just about every flywheel except the 2.8 ones. Do not need the shim behind the flywheel though.

Yes, if you order the flywheel for the 2.7 you need the spacer, because every 2.7 have a spacer (I was told).
But I talked to Ben Crisp at TTV before I bought the flywheel (to make sure it would fit my engine), and he said that they made the V8 conversion flywheels 11mm further out from the crank, so that you didn't need the spacer.
Like I said, it fit my car perfectly without any spacers.

[Jeremyboukaia]

What's the thickness of your spacer? The Allroad used two different thickness spacers depending on if there was a automatic trans or a manual trans. I own both. I can measure them when I get home. When I had a 4.2L BAS motor in my Allroad with 01E trans I wound up using the auto trans spacer.
As stated earlier in this thread, if you used a stock 2.7T DMFW, you would have had to use a shim or spacer between the flywheel and the crank. Did that get put in there? I'm not sure what happens if you don't use it; either rubbing on the block or perhaps some issue with the starter.

Sorry for the bad photo but this is the transmission and spacer it came with. Out of the Manuel 2004 allroad. I've installed the tranny with and with out the spacer. I felt like when I tryed without the spacer I had a 1" gap so I did not want to bolt down the tranny and brake anything?



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[Jeremyboukaia]

What's the thickness of your spacer? The Allroad used two different thickness spacers depending on if there was a automatic trans or a manual trans. I own both. I can measure them when I get home. When I had a 4.2L BAS motor in my Allroad with 01E trans I wound up using the auto trans spacer.
As stated earlier in this thread, if you used a stock 2.7T DMFW, you would have had to use a shim or spacer between the flywheel and the crank. Did that get put in there? I'm not sure what happens if you don't use it; either rubbing on the block or perhaps some issue with the starter.

It's been awhile ago I installed the tranny. But I remember that I had a issue with that flywheel rubbing the block. So I used a spacer that came from my auto 5hp24a flywheel. That gave me the clearance I needed. So my set up right now is 2.7t 01e tranny with 2.7t clutch and spacer bolted to a v8 4.2l 40v motor.


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[swamper8]

It's been awhile ago I installed the tranny. But I remember that I had a issue with that flywheel rubbing the block. So I used a spacer that came from my auto 5hp24a flywheel. That gave me the clearance I needed. So my set up right now is 2.7t 01e tranny with 2.7t clutch and spacer bolted to a v8 4.2l 40v motor.


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Are you talking about that super thin shim (steel maybe .060") or the heavier/thicker one which is probably like 3/16"-1/4" give/take. For between the flywheel/crank.

I agree this shouldn't be that hard. As I discussed with Ben, it seems there's two (three actually) viable options when going with a V8/01E:

1.) TTV V8 flywheel and B5S4 clutch variant. As Niebelheim has reported as using successfully. No crank/flywheel shim and no bellhousing spacer
2.) TTV 2.7T/B5S4 flywheel and B5S4 clutch. Need bellhousing spacer. Don't know about crank/flywheel shim
3.) TTV 2.7T/B5S4 flywheel made specifically for B7RS4 clutch. Again, will need bellhousing spacer, not sure about crank/flywheel shim.

Niebelheim, what clutch did you choose? B5RS4?

[Niebelheim]

Are you talking about that super thin shim (steel maybe .060") or the heavier/thicker one which is probably like 3/16"-1/4" give/take. For between the flywheel/crank.

I agree this shouldn't be that hard. As I discussed with Ben, it seems there's two (three actually) viable options when going with a V8/01E:

1.) TTV V8 flywheel and B5S4 clutch variant. As Niebelheim has reported as using successfully. No crank/flywheel spacer and no bellhousing shim
2.) TTV 2.7T/B5S4 flywheel and B5S4 clutch. Need bellhousing spacer. Don't know about crank/flywheel shim
3.) TTV 2.7T/B5S4 flywheel made specifically for B7RS4 clutch. Again, will need bellhousing spacer, not sure about crank/flywheel shim.

Niebelheim, what clutch did you choose? B5RS4?

I'm using a stock B5 S4 clutch, as instructed on the TTV site. As my car is a daily driver, I don't have many hard starts, but I have had a few rough starts, and the clutch just grips. I have also pulled heavy trailers without problem.