Transmission Removal Clutch Replacement diy Quick Version

[gabe@bwperformance]

I am so glad that after so long my diy is still getting use.

[BOUDAH]

Bump to the top! Just emailed this link to my mechanic, I hope he doesn't take it as an insult

HAHAHAHAHA thats awesome

[Rated-RR]

when bolting the transfer case back together is it supposed to be hard for them to mate or should it simply just slide together. because i don't want to force it and damage something. it slides together fine until it gets to the part where the o ring is is this normal?

[bsA41.8T]

should go pretty easily...maybe alil wiggle but it should go rite on

[Rated-RR]

Yea it doesn't does that collar have to line up is there a way to turn it witout removing the transfer case because it fell off the tranny out put shaft and only would fit on one way. If I turn the part where the axle bolts up will that do it or so I nee to turn the output shaft on the tranny?

[gabe@bwperformance]

I sent you a PM. other than rocking the engine and trans back and forth to get it lined up, the other thing you need to do is grab the driveshaft and rotate it back and forth.

[Rated-RR]

I figured it out haha. I had a stupid moment and didnt have the tranny in neutral haha. that's what happens when you remove it and install it all by yourself. but I got it. awesome right up btw. helped a ton with removal. and also installing when I couldn't remember exactly which bolts went where.

[climbingcue]

Did the job today with the help of two of my friends. There is no way you could do this job alone. Thank you Pal and Don. It is tons of work, we took some pictures to fill in where some of the missing pictures would go. Without this guide I would never found that hidden 6mm Allen bolt.

Bill

[lil_kano]

Did the job today with the help of two of my friends. There is no way you could do this job alone. Thank you Pal and Don. It is tons of work, we took some pictures to fill in where some of the missing pictures would go. Without this guide I would never found that hidden 6mm Allen bolt.

Bill

I did it by my self with like 4 jacks. haha a bit time consuming but i got it done.

[PowerDubs]

About to head down to the garage shortly and pull my trans. Thanks for the write up, I'm sure it will prove beneficial.

[PowerDubs]

Please update the orig post and mention the $#@^&#* bolt underneath the air pump, next to the oil filter housing.

[gabe@bwperformance]

haha yeah. That is a funny one. You need to loosen the upper smog pump bracket bolt and remove the 2 lower bracket bolts to get to it.

[lil_kano]

That one got you too, huh??

Please update the orig post and mention the $#@^&#* bolt underneath the air pump, next to the oil filter housing.

[sidvitious]

thanks for this instructional. i kept this with me as i went from dealer to mechanic to mechanic showing them the alternative method of doing this swap.

finally got a custom shop that would be willing to give it a try. the results are awesome. the boys at Prestige Motorsports in Livonia, MI said the instructions were spot on, but they couldn't understand the timing. meaning, how the post mentions a rough time of 3 hours to get this done.

they did however, say this was much better than following the computer based system they had compared it to.

once again, thanks for this!! (and now my R will be roaring again in 464.7 miles )

[LIFE.:R]

Pushing 80,000 and definitely going to do it myself


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I am here: http://tapatalk.com/map.php?1glswz

[cosmicgreenGTI]

I just used this post and the bentley dvd ( mostly for all tightening torques) to replace my DMF. Thanks for the write up it was very helpful. I had my brother in law help me take it out, but when I was ready to install, he was not avail. So I bought from HF an engine support bar and a motorcycle jack and got the trans back in my myself in about an hour. need to have the trans propped up on angle to get it in to get up and over the sub frame but it will go. I also removed the driver side driveaxle flange for a bit more clearance. i also put a block under the transfer case to keep that from falling down and not being aligned with the trans. once I got it high up and close, I had to lift it abit on an angle to avoid the back end hitting the body. once up and over the flywheel, it slid right on with some wiggling.

you can follow my post here to determine I had a bad DMF. http://forums.vwvortex.com/showthrea...o-I-have-a-LWF

[Mikey_M]

Thank you very much for writing this up. This is the only reason I was able to separate my transmission and transfer case.

Although the weirdest thing. The bolts on the top and bottom of my transfer case to transmission were round heads with 8mm allen inside. It was almost impossible to remove with a ratchet and allen socket as soon and the bolt came out too far the ratchet was stuck. Fun times, fun times.

[B0rin]

took me forever to find something that will work for the bolt on the passenger side




now continuing on

[Yak Meat]

need to do this potentially, i knwo my throwout is blown...

[Mantvis]

19. Remove four 16mm bolts connecting transfer case to transmission Be patient. These can take some time and be a pain but they all are accessible

Problem is i cant even see top bolts
Can someone guide me to the right direction?

[vr6fanatic]

19. Remove four 16mm bolts connecting transfer case to transmission Be patient. These can take some time and be a pain but they all are accessible

Problem is i cant even see top bolts
Can someone guide me to the right direction?

My friend and I did this last year. I believe you need to feel for them with your hand.

[Mantvis]

This might help someone, couldnt get flywheel bolts out because the whole flywheel would turn. So thought of this.

[Rudi46]

Hi guys going to pull my motor to see whats going on. but it seems that the front right wheel has no driving force. Can it be that the splines the shaft runs on could be stripped.
There was no braking sound when this happen. Only sounded like the clutch was slipping until the back wheels kicked in.

And no only the back wheels kick in, any reason for this?

Thanks

[ina04gli1.8t]

this is great, thanks! although i think i would just pay someone to replace/install my clutch cuz it would probably take me all day to do this.

plus i can't afford to get all scarred up and caloused. i'm a hand model.

Or brake a nail! God no!

[BOUDAH]

This is one of the Better DIY's thats still being used. Don't see Gabe in these forums too much anymore.

[nchiarel]

I'm actually going to be using it as a guideline for changing the clutch in my R in a few weeks since there is no Bentley Manual out yet. A lot of this looks similar so I will just have to see how it goes. If anyone has experience with the clutch in the Golf R that may be helpful, please he;p me out.

Thanks! Great write up Gabe! I'll try to do one just as good for my car.

[newcreation]

Anyone know the part number for the 6mm allen bolt that is removed from here?

[PowerDubs]

02J409359

[newcreation]

02J409359

Awesome Josh thank you. I should have known to just ask you lol.