Took upon me the job to help a colleague. Car was towed to my garage today and started immediately. I must say, have done 3 cars now with 4x4 both manual and dsg gearbox. But this is first time replacing a clutch on a MK3 octavia tdi. And what a nice development from Skoda when it comes to easy accessability to mounts, bolts and nuts. Really, it is just wonderful to work on this 150hp tdi with 4x4 compared to a MK 2 4x4. Especially around the bevelbox and the bracket to the engine block. No need to f...around with oil return pipe, take out drive axle flange, dpf or any of that s...t. Saved me at least one maybe two hours. I spent 2 hours today and gearbox is ready to be dropped.
Work steps were as follows:
- Wheels off
- Drop subframe with steering rack, used subframe guiding pins in order to not have to do an 4-wheel alignment
- Drive axle out (i took both sides) since I like to have as much room as possible. But one really need to disassemble the inner knuckle. But space is nice.
- Mark up and disconnect propshaft tie it up. Remove all lower bolts (2 I think it was) except 2 right and left side bolts from gearbox to engine
- Next was to remove air filterbox, battery and tray to get access to starter, mounts and shiftercables.
- Then I used a engine beam to support gearbox.
I hoisted the engine a bit up to loosen the mount and bracket just to check alignment on the beam. All good, and tomorrow is a walk in the park with, starter, shiftercables and shifter. Finally disconnect wires and remove gearbox mounts etc.
And voila, gearbox ready to be dropped on a gearbox lifter.
I calculated approx a total of 7 hours for the job, but I do believe that I will be done in maybe 5hours now. Thank you VAG engineers for making a diy mechanic life easier compared to work on MK 2 tdi 4x4 manual gearbox.