Those floor tiles will take some cleaning.

They will be fine Wipe clean

______

john

That's a great effort!

Both in getting your hands dirty, and also in managing to kill a clutch with that amount of flair :P

Steve

That's a great effort!

Both in getting your hands dirty, and also in managing to kill a clutch with that amount of flair :P

Steve

Agreed.

Stirling effort there - you should be proud mate. Even if you do have a nice warm posh garage with an ensuite, beer, heating and nice tiled floor to work in.

You've seen our driveway.....imagine doing all this on there.

Agreed.

Stirling effort there - you should be proud mate. Even if you do have a nice warm posh garage with an ensuite, beer, heating and nice tiled floor to work in.

You've seen our driveway.....imagine doing all this on there.

That would be interesting, Dont think id enjoy working outside this time of year.

It hasnt really taken me long at all. I thought the 6 speed box would be a barsteward to get out. but so fars its been pretty easy. Lifted the box out by myself last night and it isnt heavy at all

Update to come tonight

____

john

Did i spot skirting boards in his garage too? :eek:

Now that is posh!

Did i spot skirting boards in his garage too? :eek:

Now that is posh!

Thye were left over when we built the house, so we decided to do the garage too

cant wait to get home now and start putting it back together.

The hilux is in the body shop so i am reduced to the world of public transport, which is really poor in my area.

____

john

Public transport????? Oh no....not.....Arriva buses.....

ARRRGGGHHHH

Forgot you had your house built.

For all that don't know, this is an aerial shot of Johns house:

All good work though, dead impressed. Almost can't wait for mine to start slipping so I can pop on a 6 speeder :P

Mine will be done on a gravel drive in the freezing cold though... :( Posh git. :P

6 speeder? Box or clutch?

Thought the 130 passat came with both?

good effort john,glad to see all is going well,how much for the coilovers?

6 speeder? Box or clutch?

Thought the 130 passat came with both?

6 speed box and uprated clutch.

Only the sports got a 6 speed box, mine is an SE so its only a 5 speed. Can't justify changing it til it breaks though!!!

Great stuff matey - looks like all is well in hand, power to you!

When it's all together and running well, you'll get a great feeling of achievment, that simply dropping it off at a garage can't buy....

I asked Ross about the need to lube the spline shaft as the proper stuff is harder to come by than hen's teeth out here. Closest I could find was BMW motorbike spline lube.

Ross said that he puts them on dry - avoiding the problem of excessive grease in the first place...

Keep the pics coming!

Cheers

Bas

This little quote here can also cause clutch problems. You put the grease on the splines and the drive plate hub splines to allow free movement when dis-engaging or engaging the clutch. Without the lubrication on the splines you could have problems such as clutch judder/drag as the clutch may have problems sliding on the shaft. If the plate isnt aligned correctly you could also chew the teeth off both the drive plate and the input shaft.

Just a little information as to why its a good idea to use the correct stuff rather than Copperslip, or nothing at all.

we call that bundle of clutch remains a "birds nest" seen plenty of Fords with that in the bellhousing , especially motobility cars for some reason

i wouldn't go blowing the bellhousing out as was suggested , it might not be asbestos these days , but i wouldn't say it would be any good for you if you breathe it in , best just tipping the gearbox up and brushing out

i've used a smear of copper slip on the input shaft of every clutch i've done without any problems, it stops the plate chattering on the shaft and fretting the splines

No clutch has asbestos in now...... they have stopped using it because of the obvious saftey hazards with breathing it in.Coincidently this is why clutches dont last as long as they used to because with an asbestos clutch it could withstand higher temperature and not cook the lining like the modern clutch.

As for the second comment regarding the copperslip. Clutch manufacturers design grease to withstand very hight temperatures. The grease that we supply with all out clutch kits has been designed not to break down at low operating temperatures. The problem with copperslip is this exact fact, that it has such a low working temperature and i think it can only withstand temps up to 175 degrees, as apposed to SACHS grease which has been designed not to break down untill over atleast 400 degrees.

Another problem with copperslip is once it has reached that point of 175 degrees it becomes very think and some cars ie. Fiat punto 1.2 which has a very small hub on it with lots of splines causes clutch drag due to the problem that the grease has broken down.

How much for a sach's then eh????

well just to make you guys a little sick the price i payed for mine including a next day delivery direct from SACHS RACE ENGINEERING in Germany and inc VAT was £251

Unfortunately Germany have stopped us being allowed to buy any Race clutches now and the only place i can advise is a company called PERFORMANCE BRAKING which is up north somewhere.

Box is out!

Bloody clutch (whats left it) is totally destroyed, the pressure plate is bent :eek:

Pics below

More to come

____

john

Ok in these pictures, it doesnt look like the clutch cover is bent IMHO. The amount of lining that has trapped in the diaphragm fingers which will prevent them from sitting in the correct position. As for the plate in the middle. id say because that has no lining left on it when you have taken the input shaft out of it thats allowed it to fall down. I take it you are also replacing the dual mass flywheel aswell? oh and just a little noter on them babies * £89+vat* hehehehe

Well today has been very uneventful

Whats left of the friction plate

Hit my first stumbling block today....... the flywheel bolts were bloody tight and I managed to somehow round off one of the spline bolt heads

I think I might try drilling the head off with a carbide drill bit then removing the flywheel and extracting whats left of the bolt?

Unless someone can think of a better plan :confused:

____

John

i always find a hammer a great tool

from memory the bolts have thread lock on , so a little heat might be ok to use

how you get it out though is the problem , drilling it might work , or maybe a die grinder just to take the head off , so as o leave something there to get hold of when the flywheel is off

from memory the bolts have thread lock on , so a little heat might be ok to use

how you get it out though is the problem , drilling it might work , or maybe a die grinder just to take the head off , so as o leave something there to get hold of when the flywheel is off

Yer they do have thread lock on Gunner have a go tomorrow. Ive measured up the hole in the new flywheel and if i drill just the head off there will be 7mm showing. Ill either weld something onto this or just try and grip it with something.

cheers john

Public transport????? Oh no....not.....Arriva buses.....

ARRRGGGHHHH

Forgot you had your house built.

For all that don't know, this is an aerial shot of Johns house:

Nearly exactly the same My swimming pools bigger though

All good work though, dead impressed. Almost can't wait for mine to start slipping so I can pop on a 6 speeder :P

Mine will be done on a gravel drive in the freezing cold though... :( Posh git. :P

Bit easyer on the passat Driveshafts off and its just about out on that one Very easy indeed. Great deal of satisfaction with these kinds of job

Looking good. My engine bay is going to be similarly sparse soon. Sure hope my clutch isn't like yours though. :eek: Mine's still going very well despite what I made it do doing 2nd gear launches.

Looking good. My engine bay is going to be similarly sparse soon. Sure hope my clutch isn't like yours though. :eek: Mine's still going very well despite what I made it do doing 2nd gear launches.

yup, its really easy tbh. and the boxs are not heavy at all. Hopefully it wont, i think its extreame heat thats destroyed mine :eek: Yours might just be glazed then, some soapy water down the bell housing hole might help it alittle

If you need any tools when you do yours just give me a shout and ill post over whatever

cheers

john

Nice pictures above john :lol: you did it good style on that one Those pieces of metal that were off the disc are there to take up the initial drive of the clutch as the pressure plate and the drive plate clamp together. You may aswell try to bolt the clutch to the DMF before installation, as im sure you can mount it all as one unit.

I posted 3 sachets of grease out to you today aswell. You only need to use 1 of them, but the other 2 can be for spares. Ive also put a brief description of what you need to do aswell.

Good job your replacing the DMF too as id imagine it was in a bit of a state after the metal running around inside of it. :lol:

Good luck, and if you need any help or any advise just pm me, and ill give you my works number for the technical department and we shall try and help you as best we can

This little quote here can also cause clutch problems. You put the grease on the splines and the drive plate hub splines to allow free movement when dis-engaging or engaging the clutch. Without the lubrication on the splines you could have problems such as clutch judder/drag as the clutch may have problems sliding on the shaft. If the plate isnt aligned correctly you could also chew the teeth off both the drive plate and the input shaft.

Just a little information as to why its a good idea to use the correct stuff rather than Copperslip, or nothing at all.

I thank you for that info mate - tbh - have had an occasional prob where the clutch doesnt dis-engage after repeated use. Bought a new clutch master cylinder and then it stopped doing it - now does on occasion.

Too late to add the right stuff I guess- the inspection port looks a little bit too small to do it safely and I dont fancy going back to opening up the whole thing...

Oh well, you live and learn...

Cheers

Bas