Clutch slipping 1990 AWD Talon TSI

[evasive_one]

I just recently purchased a 1990 Talon TSI AWD. I love the thing to death.. It's so fun to drive. The only problem is.. I re-installed the transmission on the car because I had to take the original transfer case off (the last one was WORN) I reinstalled the clutch.. and everything is back together. The first test drive went smooth! AWD working excellent. Turbo, boosting like it should.. After the first stop, I took it back out and the clutch is slipping. I notice 1st and 2nd gear slip real hard. 3rd is fine if your not pushing the car too hard. Everything else works fine. I've looked through my manual and I've adjusted the pedal and everything else that has to do with a slipping clutch.. but It's still slipping! I inspected the clutch before install and everything looked great. I think it might be weak fingers on the clutch plate.. but that's the only thing I can think of. The manual says to allow 30-40 normal engine starts to let the clutch plate settle.. but I think I might need a new clutch. I was just wondering if anyone else has had this problem or if anyone might know what the problem is.

If I don't find out soon.. I might just shoot for a OEM clutch kit and see if that doesn't fix it.

 

[1bad95tsi]

Wait im confused you took out the tranny to change the t-case? why would you do that you dont have to ?

 

[evasive_one]

Sorry, I forgot to mention.. I had to replace the axle.. (not sure what it's called) that leads from the transmission to the viscous coupling. The one that uses tiny balls to keep it in place? Someone help me out. I don't remember the name.

But anyways, I reinstalled everything. I put the clutch back on. I tq'd everything according to the manual. I double checked all my work and inspected everything.. I'm just having a problem with the clutch slipping in 1st, 2nd, and a bit in 3rd. Especially when boost engages.

My first thought would be that the clutch pedal needed to be adjusted. I did that and also bled my clutch. Everything seems to be normal except for the slipping.. I inspected the clutch before install.. Everything looked good but I think it might be the fingers on the pressure plate. If it doesn't settle like the book says it should.. Should I just get a whole new OEM clutch kit?

I'm kinda stumped on this one. This is my first DSM and I'm not too sure where I might have messed up.

 

[91talon27]

Your clutch is more than likely shot.

 

[1bad95tsi]

Ok well to change axels- t-case - driveshafts -etc the tranny does not have to come out of the car . Maybe your talking about the throwout bearing?? but it sounds like the clutch is toast and if your gonna leave the car stock ok go with an oem but if you plan on upgrading the car - make it faster in other words dont bother with an oem clutch cause youll have to replace it again just put a good aftermarket in it now and save yourself the hassle