themightyquinn
Well-known member
- Joined
- Mar 7, 2005
- TDI
- 1999 New Beetle Black
Hey folks,
I've casually been considering a 5-speed swap for a few years (and even more heavily since my torque converter went out). After dropping my the pan and trans in my Passat over the winter break I realize that replacing the torque converter at this point is just kicking the can a very short amount down the road.
In the past I've noticed that despite there being a good amount of interest in the swap (and a good amount of experience and knowledge), there doesn't seem to be one consolidated thread for clutch information. There have been a few attempts but they seem to drift off and get a bit into the weeds and confusing. So I'm starting this one with an aim to consolidate all of the information there and that I hope this one will generate into one initial post which consolidates and updates with information from this and other threads.
I'll start with the information I know, or think I do, and we can update/correct as necessary. Any input on how better to organize, pertinent details, options I'm not aware of, etc. would be appreciated.
Things I'm unsure of in italics
DMF = Dual Mass Flywheel; SMF = Single Mass Flywheel
Stock 1.8T DMF
Dual Mass Flywheel with clutch
Pros: relatively cheap, potentially smoother/better transmission life due to DMF
Cons: Potentially insufficient for stock TQ levels, Insufficient for Stage 1/2 TQ. Potential for DMF failure
(Can SBC work their magic on this setup too?)
Valeo 1.8T SMF
P/N:52285615
Pros: Cheap ($316 at Amazon, $300 at Rock Auto), potentially better reliability due to SMF
Cons: Potentially insufficient for stock TQ levels, Insufficient for Stage 1/2 TQ.
Valeo 1.8T SMF + South Bend Clutch (SBC) upgrades
P/N:52285615 + SBC relining of clutch disc (and PP improvements?)
Pros: Reports indicate good reliability at stock and Stage 1/2; good availability
Cons: More expensive than some of the other options ($300 for base kit + ~$350 for SBC work + shipping both ways = $700+
Valeo 1.9 TDI SMF
P/N: 835012
Pros: Engineered with TDI (AWX) in mind, reports indicate reliable holding for stock and stage 1/2 power levels. Bolt on clutch with no additional modifications needed (Euro starter? Spacer?)
Cons: Somewhat expensive ($550-600 delivered), no US supplier/warranty.
Sachs 1.9 TDI DMF
P/N: 2290 601 032
Pros: Engineered with TDI (AWX) in mind, should provide reliable holding for stock and Stage 1/2 power levels. Bolt on clutch with no additional modifications needed (Euro starter? Spacer?). DMF for less NVH.(Sachs, so higher quality than Valeo?)
Cons: Somewhat expensive ($600+ delivered), no US supplier/warranty.
240 mm
I'm fuzzy on this
a number of Sachs/Valeo/LUK OE replacement DMF and SMF kits for AVF engines, which (only?) works for 6 speed (SMF is likely fine, DMF requires spacer and starter?)
Whitbread 240mm flywheel
Pros: Nice and heavy, SMF for reliability, supports TDI community
Cons: Rather expensive ($479 for flywheel), Only ClutchMaster clutches work (reports of poor reliability on clutch), Expensive (+$400 for FX100, +550 for FX300)
"S4" 240mm 1.8T kits
Pros: Less expensive, no modifications required, likely good grip
Cons: Lightweight SMF which may increase NVF / kill transmissions
I've got to get back to studying, but that should provide a good skeleton for comments, discussions, additions, etc
I've casually been considering a 5-speed swap for a few years (and even more heavily since my torque converter went out). After dropping my the pan and trans in my Passat over the winter break I realize that replacing the torque converter at this point is just kicking the can a very short amount down the road.
In the past I've noticed that despite there being a good amount of interest in the swap (and a good amount of experience and knowledge), there doesn't seem to be one consolidated thread for clutch information. There have been a few attempts but they seem to drift off and get a bit into the weeds and confusing. So I'm starting this one with an aim to consolidate all of the information there and that I hope this one will generate into one initial post which consolidates and updates with information from this and other threads.
I'll start with the information I know, or think I do, and we can update/correct as necessary. Any input on how better to organize, pertinent details, options I'm not aware of, etc. would be appreciated.
Things I'm unsure of in italics
DMF = Dual Mass Flywheel; SMF = Single Mass Flywheel
5-speed
228 mmStock 1.8T DMF
Dual Mass Flywheel with clutch
Pros: relatively cheap, potentially smoother/better transmission life due to DMF
Cons: Potentially insufficient for stock TQ levels, Insufficient for Stage 1/2 TQ. Potential for DMF failure
(Can SBC work their magic on this setup too?)
Valeo 1.8T SMF
P/N:52285615
Pros: Cheap ($316 at Amazon, $300 at Rock Auto), potentially better reliability due to SMF
Cons: Potentially insufficient for stock TQ levels, Insufficient for Stage 1/2 TQ.
Valeo 1.8T SMF + South Bend Clutch (SBC) upgrades
P/N:52285615 + SBC relining of clutch disc (and PP improvements?)
Pros: Reports indicate good reliability at stock and Stage 1/2; good availability
Cons: More expensive than some of the other options ($300 for base kit + ~$350 for SBC work + shipping both ways = $700+
Valeo 1.9 TDI SMF
P/N: 835012
Pros: Engineered with TDI (AWX) in mind, reports indicate reliable holding for stock and stage 1/2 power levels. Bolt on clutch with no additional modifications needed (Euro starter? Spacer?)
Cons: Somewhat expensive ($550-600 delivered), no US supplier/warranty.
Sachs 1.9 TDI DMF
P/N: 2290 601 032
Pros: Engineered with TDI (AWX) in mind, should provide reliable holding for stock and Stage 1/2 power levels. Bolt on clutch with no additional modifications needed (Euro starter? Spacer?). DMF for less NVH.(Sachs, so higher quality than Valeo?)
Cons: Somewhat expensive ($600+ delivered), no US supplier/warranty.
240 mm
I'm fuzzy on this
a number of Sachs/Valeo/LUK OE replacement DMF and SMF kits for AVF engines, which (only?) works for 6 speed (SMF is likely fine, DMF requires spacer and starter?)
Whitbread 240mm flywheel
Pros: Nice and heavy, SMF for reliability, supports TDI community
Cons: Rather expensive ($479 for flywheel), Only ClutchMaster clutches work (reports of poor reliability on clutch), Expensive (+$400 for FX100, +550 for FX300)
"S4" 240mm 1.8T kits
Pros: Less expensive, no modifications required, likely good grip
Cons: Lightweight SMF which may increase NVF / kill transmissions
I've got to get back to studying, but that should provide a good skeleton for comments, discussions, additions, etc
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