Clutch time anyone?

[ORCoaster]

Over the weekend I had the chance to replace the clutch in my 81 Rabbit. 

Just wondering what amount of time you guys spend doing this.  Now consider I borrowed a garage so I would have a level smooth floor for the floor jack but other than that I have no lift, pulleys or brute strength.  How many hours would you spend doing the following:

Removing and replacing the clutch and pressure plate.
Removing and replacing the seal on the rear of the crankshaft.
Removing the bushing, and oil seal on the front of the mainshaft.

Those were the major items and the minor ones were a set of anti vibration pads on both sides of the engine mounts and resealing the water pump on the windshield washer reservoir.   

I got the trans down and the flywheel off in good time but the inside of the flywheel was packed everywhere with parts of the clutch itself.  Between the oil coming out of the engine and the front of the trans that disc was threads away from having the rivets eating the flywheel.  I got the flange off the engine without a problem and only had to argue with the pressure plate a bit trying to keep it from moving on me.  Two wires through the engine block and securing the plate made it work.  That gasket between the engine and the flange was a bugger to remove.  I think it was just 1/8th of an inch of permatex on there.  It did not scrape off hardly at all.  But did file off fine. 

Then there was the bushing.  Just remove the throwout bearing and the pushrod and drive it out the back correct?  Well not if it is worn so bad that it is barely visible in the first place.  Nothing in hand to slip behind and pull out either.  Ended up at the VW shop where he had such a tool.  Cost me 5 bucks to have him pull it out. 

Getting the trans in by ones self didn't work and barely worked with tow guys and a strap underneath it to keep it from walking off the jack.  I spent at least two days on this repair and I can't remember it taking that long when my son and I did his Rabbit several years ago.  We even did the timing belt at that time and I think we were only at it for a day. 

So is 20 hours reasonable?  Given the equipment at hand, the single pair of hands and the difficulty of the repairs.

[CRSMP5]

3 hr r n r for mk1 diesel/carb clutch/seal job... 4.5 if cis... damb fuel system....

mk2 is 4.5 hr

mk3 020 is 4

mk3 02a is 5...


all i need is 1 person to set it on my chest to go back in... this is jack stands, both axles removed, floor jack under oil pan, bench press method... mk2/mk3 is with inner right side flange removed... mk1 optional if 90mm.. 100mm needs removed..

ive done way too many... i can r n r tranny with bolt kit and all in a additional 6-7hr... depends on how dirty it is and cleaner i have to clean the parts...

[8v-of-fury]

Hmm, 20 hours seems up there. But I have never done all those jobs at once .

My biggest maintenance job at one time was a clutch disc (oil leak destroyed it), and a HG (cause of the oil leak ) in 6-8 hours. By myself, on jack stands in my driveway.

[Dakotakid]

Seriously, why worry about how long it took? As long as things are working right, that is what matters.
I've seen quickie mek-a-nicks who perform poor work. Quite often, really. But as long as it clears the lot before it craps out.....

[8v-of-fury]

he's just trying to justify it to his wife is all, eh DAS? Next time it will be an easy 7 hours.

[CRSMP5]

trying to figure out the missing beer.... and time that disapeeared at the same moment...

[ORCoaster]

I am just wondering if I was messing up somehow.  Wife wouldn't let me tackle the clutch work until her bedroom floors were sealed and all walls painted twice.  I got that done and got to hit the garage. 

I does run well now.  All that crap in the flywheel must have been making it off weight.  It used to shake like crazy at 72 mph but today.  Who boy, did well at any speed between 65 and 75.  Could have been the additional dampening kit or the fact that all four motor mounts came off and were reset without any weird tension on them. 

I couldn't believe that clutch disc either.  Black as old diesel oil and it looked like the cat was tearing at it all around the outside. 

I should have taken pictures.  But then I would have had to clean up the garage with all the beer bottles and chip bags hanging around the place.  Seriously I only had one beer all weekend.  Laying on my back most of Friday,  I needed something to kill the aches. 

I think my son popped the trans in his car and I was at the ready with the long bolts for the top of the engine to trans fit.  He is the brute in the family.  My chest won't hold up to a VW trans sitting on it.  Frail old Phart.  DAS

[burn_your_money]

I think the first (and only) time I've done it in a mk2 it took 12+ hours. I replaced the tranny though because it got stuck in third gear. I'm not sure if I got into the clutch at all. It was a one man show, and getting that tranny in and out was a real bugger. Now that I know the scissor jack trick, it'll save a lot of time.

[R.O.R-2.0]

VW clutch replacement takes me roughly 4 hours..

including smoke/beer breaks, and breaking things, as well as trying to find parts to fix what i broke..