I think my clutch is slipping when at peak torque (standard map, 108k miles on the original clutch). When I load the engine up hard in a high gear, the revs rise then drop, then eventually the revs start to rise properly (all this happens with the same throttle position). Sometimes when this happens I get a judder at the same time. I'm assuming this is the DMF spazzing out. I always thought that when a clutch slips it would start slipping, and only grip on again when you back off the power. But it's as if this slips for a second (maybe until it gets hot), then bites (causing the revs to drop) then carries on. It never happens in normal easy driving, only when I'm really loading up the engine. Anyway......

Just looking at my options for now. Any advice would be great.

- DIY or Garage: Looks like a fairly demanding job (requires removing the gearbox by the looks of things). So hard work, or lots of hard cash I presume! I've changed engines and gearboxes before, but not on anything modern or transverse. Anyone had this work done by a garage? Ideas on cost would be great.

- Clutch/Flywheel: Seems like a genuine VR6 clutch kit and a G60 or aftermarket flywheel is the way to go.

JBS kit @ £303: http://www.jbsautodesigns.co.uk/product/3327/g60-flywheel-and-vr6-clutch-conversion-kit

ECS kit @ £316: http://www.awesome-gti.co.uk/product.php?xProd=10682&xSec=301&jssCart=e739ca96956fe6e4693d88ff5c7f7878

GSF/VW DIY kit: GSF sell a Mk3 Golf VR6 clutch kit for £95 (made by LUK). Haven't found any flywheels yet. Bolts and release bearing would come from VW I guess.

Don't really want to spend much more than £300 on the parts, but want them to be reliable and suitable for a mapped vRS (my car's not mapped yet).

Just after any feedback or advice on this really. Thanks in advance guys

Righto, here's some part numbers for making up your own VR6/G60 conversion kit. Turns out over £100 cheaper than buying the kit from ECS or JBS.

Flywheel Bolts (6) = N90206103

Clutch Cover Plate Bolts (6) = N10101001

Mk3 Golf VR6 Clutch Kit (Sachs or LUK) = 021 198 141 (Consists of Cover Plate = 021 141 025FX, Clutch Plate = 021 141 031CX & Release Bearing = 02A 141 165A)

Mk2 Golf G60 Flywheel = Lots of conflicting P/N's on this as it looks like the same flywheel was fitted to alot of cars, but all these part number should lead to the same part.

JBS quote = 037 105 273C

ECS & MJM quote = 02A 105 269B

Bolts come in at about £20, clutch kit at £85 and flywheel at £90. So the whole lot can be got for under £200.

This setup claims to be suitable for up to 250bhp/300ftlbs, with an OE feel.

Yea, I have the ECS clutch and it's ok since about half a year (k04). The change job cost about 90 euro here, and the clutch ordered directly from the US was about 350 euro.

I did look into these last year.

The ECS kit is very good valve for money and don't forget you will get a lighten flywheel.If your NOT going to uprate the turbo then i would go for this.Awesomes price for this is good as getting it direct from across the pond will work out roughly the same as carriage is the killer,plus it would be easier if you had any problems.

If you going for bigger turbo then look at a uprated Sachs clutch.You will need a uprated cover plate and clutch plate.Then you can add a G60 flywheel.

Sachs does one to handle around 270lb/ft and then 340lbft and if i remember roughly £230(270lb/ft) and £380(340lb/ft) for both parts.

HTH

Well I HAVE a bigger turbo (k04) and the ECS one is just fine (didn't get the lightened flywheel tho, I got the 20.5lbs one). A friend with a Polo 1.8T and 350+bhp got a F1 Racing clutch kit (don't remember exactly which one of them), which has only slightly better given figures than the ECS one and it holds all that power without problems.

Edited 24 December, 200916 yr by jmf

Righto, I'm back from one of my research missions with some info! As I see it there are two main paths to go down with this:

DIY Kit:

VR6 Clutch Kit - 021198141A [This clutch is common across the entire VR6 engine range, be it a 2.8 (AAA 174bhp) or 2.9 (ABV 190bhp).]

Cover plate bolts - N10101001 [6 required, to go with VR6 clutch.]

G60 10kg Flywheel - 028105269B [This flywheel is common across the G60 engine range too, so covers the 1763cc (1H) engine from the Rallye, and the 1781cc (PG) engines fitted to Corrado's and Golf GTi G60's.]

Flywheel bolts - N90206103 [6 required, to specifically suit the G60 flywheel.]

You can get a LUK (OEM, along with Sachs) clutch kit from GSF for £69.33, and a flywheel from VW for £152.28 (includes a £30 surcharge for not returning a flywheel in exchange). Assuming the 12 bolts will cost about £15-£20 from VW, lets say a DIY kit will cost you £240 all in.

4-Piece Complete Kits:

Transmech Solid Flywheel Conversion Kit - £149.22 [Never heard of the brand, also seems very cheap! Not going on my car.]

Valeo Solid Flywheel Conversion Kit - £218.44 [Good price, but I'm not sure what the quality would be like. As far as I know they're not OEM's for VAG clutches, but they are for other manufacturers.]

JBS OE Kit - £309.47 [All OEM parts, including standard G60 22lb (10kg) flywheel]

ECS Stage 1 14lbs (6.4kg) - £323.13 [sachs (OEM) VR6 clutch with custom steel flywheel]

ECS Stage 1 20.5lbs (9.3kg) - £363.08 [sachs (OEM) VR6 clutch with custom steel flywheel]

If anyone wants any links just let me know. As far as I'm aware, the standard DMF fitted to the vRS weighs 28lbs (12.7kg).

Basically boils down to whether you want a further lightened flywheel or an extra £100ish in your pocket. I can't decide! Looks like the ECS kits are very popular and effective though. What do I get? Help! :S

Edited 8 January, 201016 yr by Bodge

Update:

Just bought the G60 flywheel and bolts from Skoda, since the guy there gave me a great discount (15%). Flywheel rang in at £129 all in, which includes a £30 surcharge that I won't get back. Flywheel bolts came to £13, and coverplate bolts came to £2.

So I've spent £144, with just the £69 LUK VR6 clutch kit to get from GSF tomorrow. So there we are folks, you can get all OEM parts for £213 to do this G60/VR6 conversion. That's exactly £150 cheaper than the ECS 20.5lbs kit. Well worth the effort in my mind, and also that money can go back into the remap fund!

Nice one! And great information, thanks.

Update:

Just bought the G60 flywheel and bolts from Skoda, since the guy there gave me a great discount (15%). Flywheel rang in at £129 all in, which includes a £30 surcharge that I won't get back. Flywheel bolts came to £13, and coverplate bolts came to £2.

So I've spent £144, with just the £69 LUK VR6 clutch kit to get from GSF tomorrow. So there we are folks, you can get all OEM parts for £213 to do this G60/VR6 conversion. That's exactly £150 cheaper than the ECS 20.5lbs kit. Well worth the effort in my mind, and also that money can go back into the remap fund!

Result

Just to clear something up, because there are so many opinions on what the G60 flywheel part number should be, and incase someone else needs to know in the future.....

The correct part number that you order under with VW/Skoda is 028105269BX (the X implies it's a reconn'd part).

But the casting number found on the actual flywheel is 037105273C. I guess that's where the confusion comes in, as if you got it from a scrappy/ebay that's the only number you'd see. There seems to be lots of people on other forums that worry that they have the wrong part when they read the number cast into the flywheel. Hopefully they read this!

On to the flywheel spec, for those who care (geeks)!

Made in Germany. Made from spheroidal graphite cast iron, to the German DIN specification GGG-50. It has a timing mark stamped into it, unlike alot of the aftermarket options (I read that the ECS fly's don't have a timing mark). The machined steel ring gear has hardened teeth, and looks to be shrink fitted to the cast flywheel.

I'll weigh it accurately later on in the day at work and post up the result.

Picked up the LUK clutch kit over lunch too, so got all me bits now!

Thanks for the comments guys, glad to be of service.

The results are in!

An OE G60 flywheel actually weighs: 9.4436kg precisely! (measured using the fancy calibrated digital scales at work)

[That's 20.82lbs in old money]

Thanks Bodge, very useful info!!

Let us know when you get it all fitted. Will that be a DIY job too?

back to this mate y dont you get the £30 back?

back to this mate y dont you get the £30 back?

Funny you mention that actually, as I'm trying to sort out getting the £30 surcharge back as we speak (they recondition the used flywheels).

The parts guy at Skoda initially said because I'm returning a different flywheel to the one I've bought, I won't get the £30 surcharge back. But he's since changed his mind, and thinks he might be able to sort it for me, as the flywheel fits the same car, and the DMF is worth more anyway.

So I've dropped off my old DMF with him, and he's sent it off to try and get my £30. If it gets accepted then jobs a goodun!

If this works the total cost will drop to £183! Resultage!

He's only had it a week so I'll give them a bell early next week and let you know the result.

that sounds daft,

I thought they would give it back straight away?

I took my CV joint in the other day and I got my money back there and then in Cash too, I could of given them any old CV joint. granted it wasnt a dealer tho lol nor GFS or the like.

I hope you do get it back tho, end of the day its a genuine part you have returned.

How do you recondition a flywheel? surely its like a brake disk? or are there parts on there you can uses again?

Result if you get the money mate, but if not its no real big one lol as it was still cheap

billy