clutch replacment

[jcthelight]

does anyone have detailed instructions for replacing a clutch thanks

[Smileybug]

Get yourself a Bentley manual if you are going to be doing work DIY. Its well worth the cost.

[jcthelight]

how much they cost and where to get one

[Smileybug]

Bentley Publishers - Repair Manuals and Automotive Books


You can also always check ebay and amazon, etc.

[jcthelight]

i super charged my nb and i was looking to put a better clutch in than the oe one and i saw that i can use one from a vr6 is this true

[simonsi]

Originally Posted by jcthelight

does anyone have detailed instructions for replacing a clutch thanks

Best to buy a manual that covers it TBH, although the short answer is remove gearbox, fit clutch, replace gearbox....

Anyone´s detailed instructions are going to have to paraphrase a manual in any case...

[jcthelight]

Originally Posted by simonsi

Best to buy a manual that covers it TBH, although the short answer is remove gearbox, fit clutch, replace gearbox....

Anyone´s detailed instructions are going to have to paraphrase a manual in any case...

what do you mean by TBH and gear box u mean tranny right

[simonsi]

Originally Posted by jcthelight

what do you mean by TBH and gear box u mean tranny right

TBH = to be honest

tranny = gearbox

[jcthelight]

ok thanks now i cant seem to find a performace clutch for my 2.0 everything i find is oem and i super charged so i thought to upgrade the clutch now this guy at the local part store said he could get mine redone with kevlar any +/- to the kevlar i know itd be better than oem.

[ECS Tuning]

We have a few clutch upgrade options available, our Stage 1 Kit uses a larger clutch disc for extra holding power:

Volkswagen New Beetle 2.0 > Drivetrain > Clutch

[jcthelight]

hey does anyone know how much HP and TQ the stock clutch is able to withstand in a 2.0 NB

[vdubbugman53]

Originally Posted by jcthelight

hey does anyone know how much HP and TQ the stock clutch is able to withstand in a 2.0 NB

i think you would be lucky to have it hold over 150 hp.

to do the clutch you need to get the car high enough off the ground (safely) to get the tranny out from under the car.\

remove battery and tray and air box for plenty of room

remove the starter and the ground straps on that.

remove shift linkage and unplug speed sensor

remove both axles (8mm allen on a 2.0 or at least it was for me)

remove remaining bolts holding motor and gearbox together

put a jack under gearbox and disconnect motor mount

get under car next to jack and get ready to hold a transmission

remove jack to let tranny down..its heavy but you should be able to wiggle it loose. eventually it will be on your chest and you will have to wiggle your way out from under it


once now that that is out you can see the clutch assembly

need a 9mm 12 point socket to get the pressure plate off

take that off and then you need a 12mm triple square but and an impact gun to get the FW bold off. if you dont have an impact gun then you need a way to keep the FW from turning as you remove the bolts

if you reuse the FW then have it re surfaced

if not then clean the new FW off real well with some brake clean

then install with new clutch centering tool.

getting gear box back in is not really an easy task.

set it on a jack and pump it up there and do what you can to get it to slide back on to the motor then just put it all back together

first time be prepared to make this a 2 day adventure.

[jcthelight]

thanks man thats what i was lookin for cause my clutch dont slip when i do the 3rd to 5th test it feels like it when i hammer the pedal down like 40 mph in 2nd at 5k rpms or 60 in 3rd at 5-6k rpms so ima just go with a stage 1 from ecs tuning apparently the stock clutch aint holding so again thanks

[jcthelight]

Originally Posted by vdubbugman53

i think you would be lucky to have it hold over 150 hp.

to do the clutch you need to get the car high enough off the ground (safely) to get the tranny out from under the car.\

remove battery and tray and air box for plenty of room

remove the starter and the ground straps on that.

remove shift linkage and unplug speed sensor

remove both axles (8mm allen on a 2.0 or at least it was for me)

remove remaining bolts holding motor and gearbox together

put a jack under gearbox and disconnect motor mount

get under car next to jack and get ready to hold a transmission

remove jack to let tranny down..its heavy but you should be able to wiggle it loose. eventually it will be on your chest and you will have to wiggle your way out from under it


once now that that is out you can see the clutch assembly

need a 9mm 12 point socket to get the pressure plate off

take that off and then you need a 12mm triple square but and an impact gun to get the FW bold off. if you dont have an impact gun then you need a way to keep the FW from turning as you remove the bolts

if you reuse the FW then have it re surfaced

if not then clean the new FW off real well with some brake clean

then install with new clutch centering tool.

getting gear box back in is not really an easy task.

set it on a jack and pump it up there and do what you can to get it to slide back on to the motor then just put it all back together

first time be prepared to make this a 2 day adventure.

Gonna do the clutch this week but have 1 question. What is the 12mm triple square your talking about do you have a pic? Thanks.

[ECS Tuning]

We have triple square bits / drivers available here on the website along with photos:

Home Page > Search > Triple Square - ECS Tuning Inc

They are used in quite a few places on the Mk5, Mk6 models but they are typically found on flywheel bolts on the older models.

[jcthelight]

It looks like a torx and i think i have some of these.

[ECS Tuning]

Torx should be 6 point and the triple square are 12 point, also sometimes referred to as "spline".

[jcthelight]

Originally Posted by jon@ecstuning.com

Torx should be 6 point and the triple square are 12 point, also sometimes referred to as "spline".

Ok from what was explained to me from the dealer they said it was an 8 point

[jcthelight]

Is it really necessary to change the motor mount and tranny mount bolts?

[DZLBUG]

Originally Posted by jcthelight

Is it really necessary to change the motor mount and tranny mount bolts?

Unless you like your engine dropping to the pavement, YES!

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