TDI flywheel/VR6 clutch (228mm) - AAZ Vanagon

[Gizmoman]

1.9 AAZ is finally off the stand and ready for the new TDI flywheel and VR6 Sachs clutch.

After cleaning up the tin cover that fits between the flywheel and bell-housing and bolting it on with the three small bolts - the TDI flywheel hits the tin cover. This is because of the huge mass of iron on the engine side of the flywheel. The original flywheel is nearly flat at the backside (mount face is nearly flush with the rest of the face).

It was clear that it was hitting the tin where the tin is formed to provide an exit for a leaky seal I guess. I took the plasma and cut it off clean and touched it up with a flap disc. I bolted it back on and installed the flywheel - still hits .

It seems there is very little room for any tin at all unless it's flat near the OD. The tin I have has a raised area around the perimeter and is simply too thick in profile.
Is there a tin cover made that will fit without rubbing or should I just do without it?



Very little space


Also, the six bolts appear to be in fine shape. Should I re-use them or replace?

[Gizmoman]

OK,
The Bentley says the  bolts need to be replaced.
Is this the correct bolt?



Also, if someone can provide the part number for the pressure plate bolts, that would be very helpful.

Thanks

[mzak88]

I reused mine... So far, so good.

[Gizmoman]

Thanks but I've had a flywheel come loose - it ain't pretty and it ain't cheap

[bbob203]

They are fine to reuse just make sure to re loctite them.

[libbydiesel]

I've made a couple of plates that were just flat steel.  Basically the same outside profile, but the inside gets cut out and a little larger to go around the lip of the oil pan. 

[Gizmoman]

I've made a couple of plates that were just flat steel.  Basically the same outside profile, but the inside gets cut out and a little larger to go around the lip of the oil pan. 

Thanks, I basically beat it silly with a dead-blow and plasma'd off as needed. It turned out good.

[Gizmoman]

BTW, I also found the bolts I needed (I hope they are correct) at IDparts - suggested by theman53 after I PM'd a request to him.

I just like the feeling of having new ones holding all that steel. Besides, I lost one once on a suby swap in an old 79 and memories of that trip are not fond ones.

[Syncroincity]

I've made a couple of plates that were just flat steel.  Basically the same outside profile, but the inside gets cut out and a little larger to go around the lip of the oil pan. 

Thanks, I basically beat it silly with a dead-blow and plasma'd off as needed. It turned out good.

Exactly what I did. 5-lb hammer and trimmed w/ snips. I had to elongate a few of the mount holes.

[Gizmoman]

I've made a couple of plates that were just flat steel.  Basically the same outside profile, but the inside gets cut out and a little larger to go around the lip of the oil pan. 

Thanks, I basically beat it silly with a dead-blow and plasma'd off as needed. It turned out good.

Exactly what I did. 5-lb hammer and trimmed w/ snips. I had to elongate a few of the mount holes.

Here's a shot of the modified tin. Maybe it will assist someone in the future.

[burn_your_money]

Those bolts are TTY and should always be replaced.

[Gizmoman]

Agreed - ordered the six plus new pressure plate bolts as well, should have them by next weekend. Just wish I had thought about it when I ordered the flywheel, clutch and pressure plate. Mine is not a "set" so they weren't included.

[theman53]

Also I ran into an issue that you may or may not run into. Mine was an MKIV and I was replacing the DMF. There were 3 sizes of the XZN or triple square bits I needed. 6,8, and 10. I don't know which was needed for the SMF but the PP bolts were different sizes for sure. The 8 was used for the cv. Might want to check when you get them so you don't start and run out of tools.

[Gizmoman]

Also I ran into an issue that you may or may not run into. Mine was an MKIV and I was replacing the DMF. There were 3 sizes of the XZN or triple square bits I needed. 6,8, and 10. I don't know which was needed for the SMF but the PP bolts were different sizes for sure. The 8 was used for the cv. Might want to check when you get them so you don't start and run out of tools.

I guess I'll find out when I get em - thanks for the heads up - quite thoughtful

[libbydiesel]

If you have the capabilities, you may consider machining a groove all the way across the backside of the flywheel in order to give access to the two oil pan bolts.  Otherwise you need to drop the trans to pull the pan.