Help select clutch BHW FHN

Lotawood

Active member
Joined
Oct 17, 2017
Location
montana
TDI
2005 BHW Passat sedan
I'm getting parts for a manual swap. I have an FHN transmission/gearbox here already to replace the GMR.
I'm not sure on a clutch. I see some other threads with people deciding on a clutch.
I think I want a SMF and sounds like the heavier the flywheel the better. I see people sending their stuff to South Bend for endurance treatment.
I'm not opposed to DMF, but I don't like them as well as SMF in diesel pickups. Not very concerned with smooth and quiet on a pickup. So likely less worried in this 2005 Passat.
I see vendors selling stage 2 or 3 clutches with endurance treatment already. Those were SMF. I look for 1.8t clutch options. I see 02A, 02J and 01E offerings.

I also think I will get a stage 2 tune with 305 lb. ft. of torque. Stage 1 is 285. Not very many more dollars while I'm there with manual tune, for stage 2. Also these 5 volt glow plugs aren't working well where I'm at. So 7 volt upgrade in there as well as hard parts.

So is a South Bend Stage 2 Endurance with a 350 foot pound rating what I want? No extra shipping to get treatment. Available from my closest vendor.

I have a donor vehicle with a 1.8t gas engine; 2003 Passat. For shifter, linkage, petals, and I assume axles. Need to buy the extra transmission mount for the auto subframe.

Thanks
 

d0u8l3m

Veteran Member
Joined
Jun 16, 2014
Location
Connecticut
TDI
B5.5 Passat
Whitbread or alternative heavy SMF + a b5 rs4 clutch has been the best setup I've had so far.

I posted about it here:

 

Uberhare

Veteran Member
Joined
Sep 3, 2006
Location
Ontario, Canada
TDI
Too many.
If anyone is doing a 6 speed and wants a 240mm setup, I have a new DMF and Sachs SRE clutch sitting here. $1500 firm (CAD)
 

Uberhare

Veteran Member
Joined
Sep 3, 2006
Location
Ontario, Canada
TDI
Too many.
Just the clutch kit and flywheel. Starter is staying with the transmission and full swap. I bought these as an upgrade, but never needed to change the clutch like I thought I would,
 

50harleyrider

Veteran Member
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
I'm getting ready to put a clutch in my fhn with stg 2 tune. The DMF Luk that Cascade sells is my choice. Good for 300 ft-lb and will have the smoothness of DMF. You need to call Aaron at Cascade. He's got several of these units out there and said all the guys are happy. <$500 so not too pricey either. Mine looks nice and can't wait to find time to install it.
 

Lotawood

Active member
Joined
Oct 17, 2017
Location
montana
TDI
2005 BHW Passat sedan
Ok I will call Aaron.
I'm not doing my auto to manual conversion until this winter. So I'll see how 50harleyrider likes his.
I'm looking forward to no slush box. Everything else I drive is manual shift and I like it that way.
 

Uberhare

Veteran Member
Joined
Sep 3, 2006
Location
Ontario, Canada
TDI
Too many.
Pretty much anything that is built up for more performance. None of the stock units will hold long with a chipped BHW & 5 speed. The larger 240mm 6 speed stock setup will hold though.
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
I've got I believe some 2 years now and maybe 20 to 30,000 miles on my south bend endurance treated valeo 1.8t single mass flywheel clutch kit paired stage 2 tune 5 speed converted sedan. I'm at 260,000 miles now, I think I did the b.s. delete,timing belt and 5 speed conversion at @220k, my first clutch kit didn't last 10-15k miles.



If left stock your estimation of 6 months would probably be correct but south bend does a good job giving that 1.8t single mass valeo clutch disc much more grip.

That's over double what my 1000 plus dollar clutch masters kit lasted me and it's a clutch i don't mind driving daily. I liked unsprung 6 puck clutches in my dohc vtec Honda's with solid motor mounts more than I liked that crap fx300. Did i mention the only thing worse than the near 3000 mile break in period on the clutch masters clutch was the customer service at clutch masters? Even after the break in the clutch masters clutch was a pain in bumper to bumper traffic.

Now I don't drive my car like I stole it but i have lots of city and traffic driving so I use the clutch more than a highway mile vehicle.

I've not had so much as a slip on my valeo set up.


Avoid clutch masters at all costs. Terrible company to deal with and their customer service rep is a joke. Whitbread needs to find a new clutch supplier for his very well designed flywheel. Everything about clutch masters sucks. Look at their reviews on other vehicles like camaros, they are not highly regarded as a long lasting or street friendly clutch. Matt went out of his way to get me a discount price on a replacment clutch kit but I refuse to give clutch masters another dime. I also have zero interest in changing out a clutch every 9 months to a year on a daily driver moderately priced family sedan I use to carry my kid to school in daily. Go with valeo, send it to south bend.

The hub separating from the disk is a very common failure point for the clutch masters kits. My issue however was the so called self adjusting pressure plate lost all pressure. When removed for inspection there was little to no claiming pressure, once i broke the mounting Allan head bolts lose holding the plate to the flywheel they came out with no resistance by hand. There should be clamping pressue. They blamed the failure on heat, go figure trying to limp home on a pressure plate that isn't holding is going to develop heat. I wasted shipping to them to examine it. Once it arrived a half wit named I think Louis told me warranty was only 90 days. I wouldnt have wasted my time/money shipping across country then a week for them to deny warranty had i known this. Keep in mind he already knew the purchase date well before i shipped it. Then he made it out to be an inconvenience that I made him ship it back to me.
 
Last edited:

ksmoker

Veteran Member
Joined
Jul 19, 2013
Location
Central VA
TDI
05 Passat
I got my south bend stage 2 daily setup installed and back on the road last night. First impressions are great as far as drivability... feels like stock. I hope it lasts. I'm stage 2 tune and stage 3 colt cam. This is my first PD car and I'm pleasantly surprised by the power.

I will say, it did cost significantly more than I originally hoped. I thought I could re-use my SMF. Not the case.
 

Uberhare

Veteran Member
Joined
Sep 3, 2006
Location
Ontario, Canada
TDI
Too many.
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