Clutch

[Zxd5298]

Good morning all,
I will be doing a clutch replacement on an 06 Jetta tdi! Fun!!! Has anyone done it. I was thinking of pulling the motor I felt like that was the best plan has anyone done it with out pulling it out??? Also I want to go ahead and order the clutch now so I won’t have to wait but I see that the luk clutch haves different parts how can I tell if I need the luk or not?

 

[oilhammer]

You remove the transmission on that car to replace the clutch. It is pretty easy really.

There are several options for clutch/flywheel combinations. You can convert it to a one piece flywheel and do away with the DMF that often fails, or you can go back to the OE DMF type setup. Sachs or Luk is fine, I think the Luk one is probably more commonly preferred. It is all one piece already assembled.

 

[tactdi]

You will be removing the drivers side transmission mount, a engine brace will
be needed to support the engine when you remove the trans. You can build
one out of wood (search the inter webs for instructions), or purchase one from
Northern Tool/Harbor Freight. Don't bother using a jack and wood on the oil pan,
it could loose pressure and lower the engine while you are working, and will be in the way when you manhandle the transmission back in place.

If your EGR valve is leaking, now is the time to replace the EGR cooler, it is so much easier R&R with the trans out. Frank has an upgraded/rebuilt unit that fixes the leak.

 

[Powder Hound]

Luckily the O2J manual transaxle weighs less than 100 pounds (about 85 I think). If you have that overhead support for the engine, can also use some kind of support for the trans, jack it up into place, push the engine forward while tilting the trans to get it up into place, then get underneath so that the final few inches can be directly manipulated by you and your burly arms, then you will find that OH's opinion is quite true and it is relatively easy.

If you just try and jack it into place, you'll be frustrated and it will take a week.

And if it seems like removing the drive flanges off the trans to get that last little bit of room is a good idea, don't. Just don't. I tried that, something fell off in the final drive section, and jammed up the transaxle. That unit is still waiting for me to find some time to crack the case and fix it. It will probably be a long wait.

Cheers,

PH

 

[eddieleephd]

Yes, I made a rigid back out of two 2x4's and wedges to sit on the bolts at the edge under the hood. Then I used a hook bolt, chain, and carabeaner to go through the eye on the engine near the trans at the vacuum ball. The bolt is adjustable and will lift the weight of the mounts. It's easier to lift the engine with a jack, tighten the nut, and let the jack down. Saves the bolt a bit as well.

It is a lot less work and a lot less to disconnect to just pull the transmission and leave the engine. I would think different if it was a Tacoma and the transmission was twice as heavy. I can lift these transmissions by hand though.

Sent from my moto g(7) power using Tapatalk

 

[Mongler98]

Much easier to just pull the trans.
One tip I used was when putting it back in, get some long beefy zipties. Use them instead of bolts, tightening each one one at a time until the trans is sitting flush to the engine. This give you wiggle room to get it strait. Cut them off and install bolts when it's ready (obviously).
Another trick is to drain the trans first. Otherwise you might get a atf bath! Remove the fill first though to make sure you can fill it afterwards.
I would recommend a clutch upgrade. South bend makes very affordable upgrades. Stage 2 endurance is plenty and still has a stock feel. Inspect the fork for any bending though. It's not uncommon for them to bend when a new harder clutch is installed. You can add some welds and grind flat so the throw out bearing fits
There is also a bearing houseing brace you should install. It covers the bearing bump out.
It's a 1 day job as long as you have the right tools and nothing snaps!
I used a few 2x4s and some ratchet straps to hold the engine up.

 

[JETaah]

........Another trick is to drain the trans first. Otherwise you might get a atf bath! Remove the fill first though to make sure you can fill it afterwards.
I would recommend a clutch upgrade

Very Confusing. ATF in a manual trans?

 

[oilhammer]

I have never leaked a drop of fluid pulling one of these out, nowhere for it to leak out except the vent, and you'd literally have to flip it upside down for that to happen. And no ATF in VAG manuals (plenty others use it, though).

 

[pedroYUL]

What you want is a LuK 17-050 Clutch Set, available widely for very cheap.

It comes complete with DMF, clutch, and pressure plate, and actually preassembled. Just make sure you get the appropriate size long triple square to torque the crank bolts.

You also need a way to lock the flywheel to properly torque those bolts. Online vendors here Dieselgeek, IDParts, Cascade, Fixmyeuro, Dieselman, someone has a lock that works well.

 

[Mongler98]

atf = trans fluid in my land of stupid talk. sorry.
and yea i keep forgetting these have locked axle stubs. my bad. its happened to me many times though and happens enough that i do it out of habit. besides usually do a full service with fluids while your at it so.....

 

[Tankthecarman]

OilHammer, is there any truth to the story I heard about being able to swap in a Performance clutch and 6 speed from a VR6 or perhaps a GTI? I doubt there’s any truth to it, but a 6 speed would be sweet. If I understand correctly, it has a better final drive ratio and I’m into a little more fuel economy on the interstate.

 

[Nuje]

The 6sp. off a gasser would be a total waste - you'd still have higher revs out on the freeway compared to a stock TDI 02J 5MT.

What you'd want is a 02M (6MT) from a TDI - readily available from Europe. Lots of posts and threads here about people who have gone that route. Check out DutchAutoParts and DarksideDevelopments in the Vendors sub-forum - they're probably the most popular vendors here for those materials. I've used both and have had positive experiences with both for exactly this swap.

 

[Mongler98]

Or just put a taller 5th in what you have now.

 

[jokila]

The 6sp. off a gasser would be a total waste - you'd still have higher revs out on the freeway compared to a stock TDI 02J 5MT.

What you'd want is a 02M (6MT) from a TDI - readily available from Europe. Lots of posts and threads here about people who have gone that route. Check out DutchAutoParts and DarksideDevelopments in the Vendors sub-forum - they're probably the most popular vendors here for those materials. I've used both and have had positive experiences with both for exactly this swap.

Yeah. A six speed is for gasser engines that have a lower rpm to achieve horsepower. By adding more gears the performance is enhanced by having the engine in that sweet spot rpm range more often as the gears are change. It doesn't really improve, and probably worse, the final gearing as much, where you are going to want to be in your TDI.

 

[KCTDI]

OilHammer, is there any truth to the story I heard about being able to swap in a Performance clutch and 6 speed from a VR6 or perhaps a GTI? I doubt there’s any truth to it, but a 6 speed would be sweet. If I understand correctly, it has a better final drive ratio and I’m into a little more fuel economy on the interstate.

NO truth at all, VR6 transmissions will NOT bolt to a four cylinder block.

 

[JB05]

CoolAirVW has a you tube video that might be of interest to the OP for transmission removal.

 

[Tankthecarman]

Thanks everyone for the info. I must have been thinking about the European Market 6 speed. Probably cost prohibitive, anyway. Any suggested vendors for the 5th Gear upgrade?