Acceleration Revving Issues...

[ventureforth]

I have an '03 Golf TDI which now has a 110HP TDI out of a Passat.  When accelerating hard, the revs seem to go up towards the redline and sometimes hang up there in all gears and at all speeds.  Even cruising at 75mph in 5th, if I try to accelerate, sometimes the revs only go up to just around 3200rpm and stay there and I can feel the power, and sometimes they shoot way up to the mid or high 4000 range and either don't come down until I let up, or only after a while.  The engine never revved this way in the past (my 90HP version, that is), and it just doesn't seem normal to me.  There's a distinct lack of ooomph that was there before (when I had less power).

Is this the clutch slipping?  Or is it a boost issue and I should be looking for vacuum leaks or turbo issues?  Again, under the same conditions (or as close to same as you can get, as I've tried to repeat the scenarios multiple times to test it out), sometimes I feel the power and grip and the acceleration is nice an linear and I have torque and speed while never going much higher than 3200-3500rpm.  And sometimes, even as it approaches 4500rpm, I really don't accelerate much, and it just feels like it's revving for no good reason.

Thoughts?

[honda_is_the_best]

check clutch. do you know what clutch slip feels like?

[ventureforth]

I think so.  I think that's what I'm feeling.  Have been reading posts on this board and some of them sound like they're describing this phenomenon.  Clutch should be good, though, which is why I wonder.  It was totally fine before the engine swap, and it's not like I upped it to 165HP and 250ft./lbs. (that's coming, though,  when the time is right.  I have a Malone tune waiting in the wings.  ).  I did have some vacuum leak issues right after the swap, but took it back to mechanic and he claims to have fixed them.  I believe it, too, because with the leak I could barely get to 70mph, and now I can happily cruise at 80-90mph.  It's only under acceleration that it's an issue.  FYI, I'm also leaking oil now, which I need to look into.  Don't know my oil pressure as there's no gauge, but there's no warning light, either.  Could oil pressure cause issues like this?

How would you describe clutch slippage?

Thanks.

[honda_is_the_best]

let the clutch out, the tires dont spin, but the engine revs way up. should be linear. should darn near be able to predict RPMs solely on speedo reading. if your engine is revving up, and your speedo is not going up, theres a darn good chance its a slippin clutch. if you let off power for 2 seconds or so, then get back into it, does it still slip? because usually thats what a clutch will do when its starting to slip. it will slip when you overpower it, till it grabs ahold of the flywheel, then its just like normal. unless your clutch is so far gone that you can slip it in any gear, without having to let the clutch out just wrong. if you can be going down the road, in say, 4th gear, and floor it. no shift changes.. it should pull and grab. if your engine revs way up and the speedo doesnt show the vehicle moving faster, its pretty much a sure thing that the clutch is either toast, or really really glazed.

[ventureforth]

Sounds about right.  Would a vr6 clutch work with my tdi?  And would it be an upgrade?  I ask because I  might have a god one lying around.

[honda_is_the_best]

im not positive if a VR clutch works or not, i think they are different.. someone more familiar with VRs and TDIs should answer that question. but i think they are different.. but dont quote me.

[ventureforth]

Did some research.  Vr6 would work but only with g60 flywheel.  Earlier mk4 tdi luk clutch is better than my sachs.  Any recommendations on a modest priced performance clutch?  Should I go aftermarket, or go OEM back either back in time to 1999, or another application (what would be an upgrade)?

[2strokesmoke]

Maybe a rear main seal,leaking oil onto the clutch ? Would explain both the oil leak and the clutch slipping 

[honda_is_the_best]

single mass flywheel is the upgrade, i dont know what years they came on for sure.. but i know they were WAY BETTER.

[ventureforth]

So it turns out oil leak was coming out of the crush washer on turbo oil feed, so not effecting the clutch.  Good thought, though.  So, a new clutch is in order.

So, here are some contenders:

http://www.mjmautohaus.com/catalog/product_info.php?cPath=2_6_17_43_161_5195&info=Valeo_06A105265_Clutch_with_Single-Mass_Flywheel_Kit_22lbs_OEM&products_id=2737

http://www.mjmautohaus.com/catalog/product_info.php?cPath=2_6_17_43_161_5195&info=Sachs_K7003802.ELWG60_VR6_Clutch_with_Eurospec_Flywheel_in_228mm_for_5-spd_14lbs&products_id=401

Anyone use Valeo?  Is Sachs the better choice here?  And for the same price on the Sachs I can get either a 14lb or 22lb flywheel.  Lighter is better in this case, no?

Thanks.

I know there are even stronger clutches, but even my Stage 2 Malone tune only gets me to 228ft/lbs., and that's about as far as I plan on going, so I'm thinking these will suffice.

[honda_is_the_best]

So it turns out oil leak was coming out of the crush washer on turbo oil feed, so not effecting the clutch.  Good thought, though.  So, a new clutch is in order.

So, here are some contenders:

http://www.mjmautohaus.com/catalog/product_info.php?cPath=2_6_17_43_161_5195&info=Valeo_06A105265_Clutch_with_Single-Mass_Flywheel_Kit_22lbs_OEM&products_id=2737

http://www.mjmautohaus.com/catalog/product_info.php?cPath=2_6_17_43_161_5195&info=Sachs_K7003802.ELWG60_VR6_Clutch_with_Eurospec_Flywheel_in_228mm_for_5-spd_14lbs&products_id=401

Anyone use Valeo?  Is Sachs the better choice here?  And for the same price on the Sachs I can get either a 14lb or 22lb flywheel.  Lighter is better in this case, no?

Thanks.

I know there are even stronger clutches, but even my Stage 2 Malone tune only gets me to 228ft/lbs., and that's about as far as I plan on going, so I'm thinking these will suffice.

i would use the sachs clutch, with the 22lb flywheel. unless you plan on running this engine to 6 or 7k rpms.. but it sounds like this is a fairly stock daily driver.. all the valeo clutches ive dealt with, i didnt really like. they seem cheaper than others in feel and quality. ive never had a valeo clutch get old and die like it was supposed to, they always die early, from my experiences.

sachs super set clutch right? blue or green box? they are good ones.. 
14# flywheel for high rpms/racing
22# flywheel for a daily driver/better torque too.

is this setup for the dual or single mass flywheel?

[ventureforth]

Single mass.  So it sounds like 22# sachs is the way to go as the torque is more useful to me than the high rpms.