Okay time to try clutch job

[dankcorey22]

Okay my brother is needing a new clutch and flywheel in his 01 Jetta ALH. Im going to do the job this is my first clutch job on this type car. Can someone tell me some tips and clues. He is getting a SMF and stage 1 clutch

-What special tools will i need?
-Will i need to remove axels completely?
-Anything tricky before i stumble across them?

I plan on doing it next week so i still have time to order the special tools.

Thanks everyone

[nathan_b]

Those 02as are heavy sobs. it's quite a workout.

Just replace the flywheel? pressure plate bolts. These engines are weird because the flywheel and clutch assy is like backwards from a conventional setup.

Remove the drivers axle but leave the pass.

torque all bolts on assembly.

and remember to remove the gear box you have to "rotate" it counter clockwise to get the axle flange over the engine block.

It'll seem near impossible the first time or two, but you'll figure it out.

Depending your skill and equipment it's a 6-8+ hour job. Not too bad, I've always liked starting them mid afternoon, getting gear box off, new clutch ect on and lined up. and leaving. Come back next day and put gear box back in. It's quite a workout physically removing and installing an 02a. just take your time.

I personally wouldn't touch the rear main seal unless it's leaking.

Also, check the clutch arm on the transmision for damaged clips or being bent or cracked. Make sure to replace the throw out bearing too, it's not submersed in oil like the 020s.

It's ok if the new clutch is a little noisy too, don't be too alarmed.

[Quantum TD]

Good advice. The last one I did, the release bearing "fork" was annihilated, along with the lower pivot ball/bolt. Thankfully, I had a spare 02A laying around for the parts.

If your brother hasn't already bought the kit, get the VALEO kit. It comes with just about everything you''ll need (aside from any broken parts specific to the trans itself like the bearing fork). That means, flywheel, clutch, bearing, bolts, grease, clutch centering tool, etc. And the quality is fantastic.

I did mine on the floor off jack stands. I completely removed the axles, just to make the install easier, I supported the motor with a separate floor jack, and then when I went to install the trans, I lifted it into place with another floor jack. It's not too bad. Just get it to the right elevation, rotate the trans, and it will slide right in.

And, if you're on the floor, 6-8 hours is about right on for time.

[R.O.R-2.0]

not a TDI specific piece of info, but i set the trans under the car, then reach thru the engine bay, pick up the trans, then set it on the engine from up above. i found out its alot easier pulling the trans up into the engine bay, rather than pushing it up from below it..

[8v-of-fury]

Kevo I agree with you on that, using different muscles all together pulling it up from above. However I do believe the 02A is quite a deal heavier than the 020.. Like almost 25lbs. I mean sure 25lbs isnt that much.. but on top of 75lbs already, it adds up lol.

[Powered by Spearco]

I always replace the rear main seal reguardless of mileage. Also the trans input shaft seal.

When pulling an 02A or 02J trans, I pull off the Pass.side axle flange. Makes it so much easier fussing with
alignment.

[dankcorey22]

thanks for the tip guys! im doing it on the ground with jack stands so it will take a bit longer probably.

what about holding the flywheel in place while torqueing down the FW bolts? How do yall do that?

what size triple square is the axel flange bolts? i dont want to have any trans fluids to come out tho, best ways?

This is the kit he is getting
http://shopping.boraparts.com/product_info.php?cPath=21_26_33_51&products_id=41

[R.O.R-2.0]

thanks for the tip guys! im doing it on the ground with jack stands so it will take a bit longer probably.

what about holding the flywheel in place while torqueing down the FW bolts? How do yall do that?

what size triple square is the axel flange bolts? i dont want to have any trans fluids to come out tho, best ways?

This is the kit he is getting
http://shopping.boraparts.com/product_info.php?cPath=21_26_33_51&products_id=41

i use a bell housing bolt threaded in to the block, then hold a pry bar in the teeth of the flywheel, and against the bolt to keep it from turning..

8mm triple square for the axles.

if you dont want any trans oil coming out, then drain it. and might want to do as josh suggested and remove the pass side axle flange, then it will come off the engine alot easier..no need to twist the differential sky high that way..

and you will prolly want a buddy to help you. i personally do all my VW trans jobs alone, but im part Goliath, and that makes things alot easier usually..

[cevans]

If you haven't done this job before you should NOT try it alone.  For what its worth, hints below:

1) Put car on lift or jack stands.
2) Undo inner CV joints.
3) remove three ball joint bolts on the locking plate - this will allow you to swing the knuckles and axles out of the way.

Get the scissor jack out of the back of the car, you need to swing the engine forward to get the transmission out, so place the flat end of the scissor jack on the block and the other end (the one that you'd put on the pinch weld) on the lip on the subframe.

Two people can easily lift the bell housing to get it out and put it back in.

[Quantum TD]

thanks for the tip guys! im doing it on the ground with jack stands so it will take a bit longer probably.

what about holding the flywheel in place while torqueing down the FW bolts? How do yall do that?

what size triple square is the axel flange bolts? i dont want to have any trans fluids to come out tho, best ways?

This is the kit he is getting
http://shopping.boraparts.com/product_info.php?cPath=21_26_33_51&products_id=41

GOOD GOD, I hope you didn't buy that kit. The clutch kit is fine, but those Sachs Flywheels are pure China GARBAGE. Read on to find out:

http://forums.vwvortex.com/showthread.php?4898911-Before-you-consider-converting-to-single-mass-flywheel...&highlight=sachs

http://forums.vwvortex.com/showthread.php?4898915-If-you-think-you-need-a-new-flywheel-think-about-this...&highlight=sachs

http://forums.vwvortex.com/showthread.php?4898920-If-you-think-you-need-a-new-flywheel-think-about-this...&highlight=sachs

[dankcorey22]

No i havnt bought the clutch yet. He said he could wait about 3 more months till it gets warmer.

What Clutch and Flywheel is good for a good price as that one was?

[Powered by Spearco]

There is a different way to pull the axles out with out altering/changing the alignment.

I unbolt the front bolts at the front controll arms after unbolting the swaybar end links and the 12pnt. 30mm nut and swing the controll arm out to gain clearance. No need for a front end alignment afterwards.

[Quantum TD]

No i havnt bought the clutch yet. He said he could wait about 3 more months till it gets warmer.

What Clutch and Flywheel is good for a good price as that one was?

Get the Valeo kit. It's a bit pricier, but the quality of the flywheel is MUCH better. I'm not saying the Sachs won't fit, but you'll encounter problems in mounting, just like I did.

http://www.idparts.com/catalog/product_info.php?products_id=656

You can probably get it elsewhere for less. I got mine at jobber price for like $350.

Yeah. Looks like Autohauz AZ has it for about $390 with free shipping. WELL worth the extra $50 in my mind.

http://www.autohausaz.com/search/product.aspx?sid=l4rusgqeiozust45gh1oxp45&partnumber=52255602

[dankcorey22]

No i havnt bought the clutch yet. He said he could wait about 3 more months till it gets warmer.

What Clutch and Flywheel is good for a good price as that one was?

Get the Valeo kit. It's a bit pricier, but the quality of the flywheel is MUCH better. I'm not saying the Sachs won't fit, but you'll encounter problems in mounting, just like I did.

http://www.idparts.com/catalog/product_info.php?products_id=656

You can probably get it elsewhere for less. I got mine at jobber price for like $350.

Yeah. Looks like Autohauz AZ has it for about $390 with free shipping. WELL worth the extra $50 in my mind.

http://www.autohausaz.com/search/product.aspx?sid=l4rusgqeiozust45gh1oxp45&partnumber=52255602

Thanks man i really like that one from autohausaz looks like quality is not an issue their

[cevans]

Contact Bora about the flywheel rather than taking a random post from VWVortex as bible.

The Sachs kits we carry we match with a non-Sachs, 22lb flywheel with a correct ring gear, timing marks and bolt holes.  I'd suspect Bora also has a nice quality flywheel, so I'd ask!