Kamloops BC TDi Clutch

[Da TOW'D]

Hi,
My grandson has a 2002 TDi Jetta that needs the clutch/flywheel replaced.
I'd like to hire some body to lend a hand . A second set of hands make that job go a lot smoother. He has the new parts.
As soon as possible
Anybody interested send me a private message
thanks
Hank
_________________
'57 type 1 Blackberry
'58 SC Ruf
'62 type 3 Notch
'69 Karmann Ghia Convertible (new project)
'92 Eurovan Willy
'99 Eurovan Winnie
and NUTS

[Da TOW'D]

I was hoping somebody in the Kamloops area could lend a hand.
I'd make it worth your time.
thanks
Hank
_________________
'57 type 1 Blackberry
'58 SC Ruf
'62 type 3 Notch
'69 Karmann Ghia Convertible (new project)
'92 Eurovan Willy
'99 Eurovan Winnie
and NUTS

[Da TOW'D]

Looks like plan B is what I'm going to do
Load my tools needed and drive 10 hours to Kamloops
he has his own set of tools but I know mine like the back of my hand
it will be good to do the job with him
his first rodeo but not mine
Hank
_________________
'57 type 1 Blackberry
'58 SC Ruf
'62 type 3 Notch
'69 Karmann Ghia Convertible (new project)
'92 Eurovan Willy
'99 Eurovan Winnie
and NUTS

[skills@eurocarsplus]

good luck

it's a shitty job a lift, couldn't imagine doing it on your back.
_________________

[Da TOW'D]

thanks Skills
I do have a 2 post lift but it is too hard to move
he will be doing the under car part on a sheet of plywood
it should be a good lesson for him
cheers
Hank
_________________
'57 type 1 Blackberry
'58 SC Ruf
'62 type 3 Notch
'69 Karmann Ghia Convertible (new project)
'92 Eurovan Willy
'99 Eurovan Winnie
and NUTS

[TDCTDI]

Ah, it ain’t that bad, I got them down to about 3hrs. Laying down under it in a parking lot is easier on your back than standing the whole time. You don’t even need to remove the wheels.



MAKE SURE THAT HE GETS A SINGLE MASS FLYWHEEL & CLUTCH CONVERSION!


Hang the engine with a support bar, remove the air box, battery & tray, mark the position of the shift cables in the ends, push the spring loaded retainers & twist them about 1/3 turn to lock them open, remove the three bolts holding the shifter cable bracket to the trans & slide them out of the way.


Remove the two bolts to the slave cylinder & hang it out of the way.

Remove the starter.

Remove the brace from the trans to the transmission mount.

Unplug the speed sensor.

Remove the ground strap & the top two bolts holding the trans to engine.

Then roll under the car, remove the u shaped heat shield & unbolt the inner CVs.

Remove the “dogbone” mount.

Unbolt the P/S line from the trans.

Then, remove the four bolts holding the steering rack to the subframe, and the two bolts attaching the exhaust support to the subframe.

Now you can remove the bolts holding the subframe & let it drop, you usually need to coax the steering rack to let loose of the subframe with a pry bar (guide dowels on the driver side bolts) , it will suspend itself by the balljoints.


Now you can move the drive axles out of the way & tie them out of the way with some coat hangers.


Go back up top, remove the two 18mm head bolts holding the transmission mount to the bracket & then lower the engine down until you can get to the three 16mm head bolts that hold the mount bracket to the transmission. WARNING, these bolts are installed at the factory with locktite, you need to heat the metal around the threaded area with a torch or you will likely break the bolts. Also, be sure to clean & lube the exposed threads on the other side of the bolt, they extend beyond aluminum casting & get pretty rusty.


Drain the transmission fluid if you want, you might wear it if you don’t, but I usually don’t.

With that done, remove the 6mm Allen socket bolt in the passenger side output flange & remove the flange. (It is spring loaded, but it doesn’t go far.)


Now, just roll back underneath & remove the 18mm bolt on the back of the engine going to the transmission (just below the output flange.)

Then the three 16mm bolts holding the transmission to the oil pan.

Slide your floor jack under the transmission, towards the rear of the main body, but not the bell housing.

Gently pry the two apart &lower the transmission, while weaving it through the power steering line & subframe.

After installing new flywheel & clutch, reverse the disassembly process.
_________________
Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.


GOFUNDYOURSELF, quit asking everyone to do it for you!


An air cooled VW will make you a hoarder.


Do something, anything, to your project every day, and you will eventually complete it.

[Da TOW'D]

Thanks for the tip on the 16mm bolts TDCTDI
I've not had any problem with those bolts before but I'll use your heat trick this time --just lucky before
I'm hitting the road at 0630 tomorrow
Cheers
Hank
_________________
'57 type 1 Blackberry
'58 SC Ruf
'62 type 3 Notch
'69 Karmann Ghia Convertible (new project)
'92 Eurovan Willy
'99 Eurovan Winnie
and NUTS

[skills@eurocarsplus]

[Shonandb]

Da TOW'D, how did you make out?
_________________
*******************************
76 Westy with a 2.5L Subaru SOHC + Vanagon (010) Automatic Transaxle
Build & Trip Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=758760
Previous 1973 Panel Bus:
Click to view image

[Da TOW'D]

Well it was a great adventure working with my grandson
the working conditions were not as comfortable as working in my shop with a cement floor and hoist and heat.

Instead we did the job outside on a gravel parking lot, the shop space deal fell through, but my grandson did the on the gravel under the car things and I did the top side stuff.

First day the weather turned nasty I left Dom to tend to the axle bolts while I headed off to Canadian Tire for a tarp and rope.
We had to remove the left lower ball joint bolts to get more room by moving the drive axle out of the way.

Then the transaxle came out OK.
I made up a metal tool to bolt to the flywheel so I could keep the flywheel from spinning while undoing the bolts
The Dual Mass Flywheel was loose and the pressure plate had a broken finger the clutch disc was very thin.
The throw out bearing came out in many pieces.

We cleaned everything up with Brake clean and Scots bright pads and replaced the rear main seal.

We put the new single mass flywheel on and torqued it and installed the disc and pressure plate. I said that is enough for today. Dom climbed out and I looked to see what things looked like and saw the thin steel plate that goes between the engine and transaxle laying on the gravel. doh

He tried to put it on but it has to go on before the flywheel so we pulled the flywheel and clutch off. Called the VW place in Kamloops to see if they had new torque to yield flywheel bolts and they did.

We found out the Axle seals for the transaxle were too big so called VW again but they didn't have any in stock but would have then the next day in the morning.
We drained both the engine and transaxle oils and refilled with new. New oil filter installed

We got everything back together the next day and took it for a drive - A OK
I found the crankcase vent hose was cracked so we ordered one from VW.

I got to spend some time with my son who lives in Kelowna who drove up to see if he could help.

I left and headed home another 10 hour drive.

I know how to have fun

thanks for all spiritual advice guys

Hank
_________________
'57 type 1 Blackberry
'58 SC Ruf
'62 type 3 Notch
'69 Karmann Ghia Convertible (new project)
'92 Eurovan Willy
'99 Eurovan Winnie
and NUTS

[busdaddy]

Sounds like a real character building experience for everyone, well done!

So is there hope for the Grandson doing his own work in the future?, you know.. Give a man a fish Vs; teach a man to fish...?
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[Da TOW'D]

The floor jack didn't work so well with a "floor"" like that
We lifted the transaxle using a small ratchet strap with the hook in the TDC hole in the trans and the top hooked to the engine lift brace

Hank
_________________
'57 type 1 Blackberry
'58 SC Ruf
'62 type 3 Notch
'69 Karmann Ghia Convertible (new project)
'92 Eurovan Willy
'99 Eurovan Winnie
and NUTS

[Da TOW'D]

well there are more lessons for grandson to learn
He drove the Jetta like he was leading the Dakar rallye and the timing belt broke going 110kms up hill.
He was told by the PO that the belt was replaced last year.
I looked at the belt around the cam gear and it looked good.
We will load it on a trailer and bring it up here another 10+ hour drive.
Better working conditions and I have another running ALH engine
$#!t happens
_________________
'57 type 1 Blackberry
'58 SC Ruf
'62 type 3 Notch
'69 Karmann Ghia Convertible (new project)
'92 Eurovan Willy
'99 Eurovan Winnie
and NUTS

[Shonandb]

Sorry to hear that! I was in Kamloops the weekend before you posted but didn't have the time to drive back up and help out unfortunately. I'm sure that your Grandson values your help and the time you are spending with him!
_________________
*******************************
76 Westy with a 2.5L Subaru SOHC + Vanagon (010) Automatic Transaxle
Build & Trip Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=758760
Previous 1973 Panel Bus:
Click to view image

[Da TOW'D]

Yes thanks I was young once a real long time ago.
Instead of basic transportation he wants to see what it will do.
His father left the scene just after he was born so I've tried my best to teach him things.
_________________
'57 type 1 Blackberry
'58 SC Ruf
'62 type 3 Notch
'69 Karmann Ghia Convertible (new project)
'92 Eurovan Willy
'99 Eurovan Winnie
and NUTS