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VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old March 19th, 2018, 20:54   #1
simonbee
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Default Manual transmission clutch package

I was wondering what people are using for clutches when doing 5 speed manual conversions and what result they had with it.

I am gathering hardware for another conversion and wondering if the clutch package I used was an overkill. This what I used: South Bend stage 3 Daily with a LUK DMF made for 1.8T gasser. It is rated for 395 FT-Lb of torque. I also have a stage 1 malone power upgrade. The cost of this package was close to $1000. I have about 12K miles on it now with no issues. I like to find cheaper package but as reliable.
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Old March 20th, 2018, 07:40   #2
PickleRick
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For not much more you can use the whitbread 240mm clutch kit (300 model i think) which is listed as Matt's personal favorite on his site. It doesnt require a spacer. It has stock pedal feel and will handle anything the motor can put out until you start getting into mods that require heavier duty rods and head studs.

For a budget, if i was not going to use anything other than a stock horse power tune I'd use the heaviest single mass 1.8t passat flywheel kit i could find and a clutch kit capable of holding a 250 ft/lbs of torque.


Should be able to budget one of those for sub 500 bucks..maybe sub 400 if you look for deals/sales.

That's the info I've found, but when getting into kits that handle tunes you're looking in the 700 to 800 range and up
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Old March 20th, 2018, 09:05   #3
zzdiesel
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I used the clutch from Franz. Single mass flywheel. Stage 2 tune. 2 years and approaching 40000 miles with no problems. I do wonder if with the delete kit if a DMF flywheel would be smoother.
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Old March 20th, 2018, 09:24   #4
Jake Brake
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Default My clutch slipped

I too went with the european smf cluch and flywheel grom Frans. It was fine until i got my stage 2 tune. It slipped everytime you gor into 4th and 5th gear and got the least bit frisky with it. I had to have Southbend reline my clutch disk with a better material. I do tow a fairly heavy load ever now and then.
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Old March 20th, 2018, 11:54   #5
richmondvatdi
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I bought a recently-converted tdi wagon from a forum owner 2 years ago. I've put 60,000 pretty easy miles on the 1.8t DMF/clutch setup. The clutch is grabbing when stsarting out from a stop and the DMF is beginning the death rattle. No more messing around for me, after reading everything I could find on this topic I just ordered this setup:

https://whitbreadperformance.com/col...=4708260118557

I really hope it's the end of my clutch issues for a while.
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2003 Jetta GL TDI Wagon, 5-speed, 340,000 miles (9/2017)
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Old March 20th, 2018, 16:56   #6
PickleRick
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I don't have any personal experience with the DMF but I've heard too many failures with them on the little 1.8t to trust it with the torque (and torque pulse) from a diesel.
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Old March 20th, 2018, 18:02   #7
richmondvatdi
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Quote:
Originally Posted by PickleRick View Post
I don't have any personal experience with the DMF but I've heard too many failures with them on the little 1.8t to trust it with the torque (and torque pulse) from a diesel.
Not sure I would generalize to all diesels. I put a Luk DMF in my ALH A4 (Malone Stage 2) at 250k. It's pushing 350k with zero issues. The 1.8T DMF may be exceeding its limits on a mildly tuned PD though.
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2005 Passat TDI Wagon, 5-speed, 230,00 miles (9/1017)
2003 Jetta GL TDI Wagon, 5-speed, 340,000 miles (9/2017)
2003 Jetta GLS Wagon, 5-speed (conversion), 250,000 miles (9/2017)
2013 CC Sport, 6-speed, 2.0 TSI, 78,000 miles (9/2017)
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Old March 20th, 2018, 18:05   #8
Uberhare
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I used the stock 240mm DMF & clutch setup for 5 years without issues. (tuned)
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Old March 21st, 2018, 03:22   #9
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I might be a little over cautious as one of my BHW motors (possibly 2 of them) is going into my boat so after reading/hearing a few stories of them coming apart, im a little hesitant to trust one. Below a car motor is asphalt. Below a boat motor is fiberglass and then an ever changing depth of water. Tow boats USA doesn't cover a sinking. Solid mass for me please and thank you. Just think of the poor manatee. What if my boat sank and they got all my beer? Fat slow vegetarian frat boys. There would be memes.
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Old March 21st, 2018, 10:11   #10
blazen71
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I didn't do the swap on my car, but the guy who did it 6 years ago believes he used a euro dmf set-up. At 30k miles it slips in 3, 4 and 5 if I give it more than part throttle. Hope that helps.
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Old March 21st, 2018, 11:40   #11
simonbee
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One of the reason I used a DMF was wear and tear on the sincros. I also have a Geared BSM. I assume the 240 mm flywheel arrangement is used in the V6 gassers? This also required a different starters than the original TDI? Spacer?
Thanks for all you opinions.
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Old March 22nd, 2018, 07:22   #12
50mpgtdi
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The flywheel/clutch I used for my swap was a no name single mass flywheel and 6 puck solid disc for a 1.8t passat from ebay. It's holding torque is great. The only recommendation I would make is to get one that has a sprung disc. It can be a little harsh on takeoff with both the flywheel and the clutch disc being solid. But it was cheap and served my purpose at the time of the build. Under $400 for the whole set up.
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Old July 10th, 2018, 08:57   #13
50mpgtdi
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Just to update my input in this thread.....I've learned the hard way that solid light flywheel and solid disc is not a good combination. Very hard on syncros. The aforementioned 6 puck ceramic killed off 2 transmissions so I changed to a solid organic disc and it has now KOed another transmission. I will be changing to a heavier flywheel and disc, either dual mass flywheel or sprung disc, whichever I find to be more suitable to my application with the Malone stage 2 tune I will be getting.
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