Golf 4 1.9 TDI Clutch

[KemppiFrog]

Friend has asked me to assess changing the clutch as slipping. Da toob tells me that it can be done by pulling the gearbox off sideways and leaving the engine in place (maybe tilting it a bit..)
Car is a spare and not worth much, but comes in handy for guests and friends. Bits will be around €200 (Valeo) and I have the kit to do it.
Any hiccups that might make it tricky?

Cheers

KF

 

[Matchless]

I did one for a mate a few years ago, was not toooooo hard, on a lift, doable on the floor if you are fit enough!

 

[steveo3002]

box needs to come off

 

[welder_dave]

If its a 6 speed box its surprisingly heavy. Easy job to do in a workshop with a lift. And another pair of hands to lift box in/out. Its quite probably got a dual mass flywheel too.

 

[KemppiFrog]

Thanks, it is a 2003 motor, so prob not dual mass? 5 speed manual.
No lift, but lots of axle stands and jacks, plus a hefty engine crane.
Gonna have to do the same for my DCI Kangoo soon. Looks to be the same. Current prob is the ABS bloc. Failed the CT (MOT) and not that easy to find a fresh one. Have to say, Kangoo is almost entirely original, 'cept for a recent starter motor. On 380K km... with a lot of towing of boats.

 

[hotponyshoes]

I did my other half's on the drive by myself a good few years ago but don't remember anything tricky about it.
Although hers was a 2002 I think and that definitely had a dual mass on it.

 

[steveo3002]

think theyre all dual mass

 

[DickyDoDah]

You don't need to spend £200 on it, the BayOfThieves is for once a good place to get a clutch kit. I found this one for only £72.60. Might not be exactly the one you need but they always ask for the Reg to check.

Clutch Kit 3pc (Cover+Plate+Releaser) fits VW GOLF Mk4 1.9D 00 to 06 B&B Quality 5055188212559 | eBay

Find many great new & used options and get the best deals for Clutch Kit 3pc (Cover+Plate+Releaser) fits VW GOLF Mk4 1.9D 00 to 06 B&B Quality at the best online prices at eBay! Free delivery for many products.

www.ebay.co.uk

As others have said the gearbox is surprisingly heavy and an unbalanced awkward shape. If you can support it from above it will make it much easier to slide out and back in. If you support the engine with a jack you can tilt it down a bit to make it easier to get past the inner wing/ chassis rail. I would also advise taking off everything you can that might get in the way as you will only find out that it should of come off when you are under the car holding up a loose gearbox with both hands Not a nice place to be.

 

[mr haynes]

Should be dmf from memory.
Engine crane is your biggest friend. Can manipulate box without killing yourself
Along with a decent jack
Only thing to worry about is the weather

 

[KemppiFrog]

Thanks everybody. Any complication with the dual mass, as long as it is in one piece?
Weather a bit carp her at the mo, sheeting down, but I have a lean-to shed , slight clear out needed... drafty, but dry.

 

[Moose McAlpine]

They're not too bad on the floor. 5-speed is much easier than 6-speed, which is already easy. Both have a dual mass flywheel.

You'll need M8 triple square for the driveshaft bolts, and a 9mm 12-point for the clutch bolts.

If you want to make the job really easy, get an engine support bar and a ratchet chain hoist.




(That's a 6-speed.)

 

[hotponyshoes]

Thanks everybody. Any complication with the dual mass, as long as it is in one piece?
Weather a bit carp her at the mo, sheeting down, but I have a lean-to shed , slight clear out needed... drafty, but dry.

No but they don't last for ever.
I'd consider Valeo at £200 to be a decent clutch. I'm not sure I'd bother to spend £200 on it without doing the flywheel as well?

I'd either fit the cheapest clutch I could find and hope for the best or fit a valeo clutch and flywheel and expect it to outlive the rest of the car..

 

[Bobupndown]

They're not too bad on the floor. 5-speed is much easier than 6-speed, which is already easy. Both have a dual mass flywheel.

You'll need M8 triple square for the driveshaft bolts, and a 9mm 12-point for the clutch bolts.

If you want to make the job really easy, get an engine support bar and a ratchet chain hoist.

View attachment 421976
View attachment 421977

(That's a 6-speed.)

Is the engine support bar home made? Does it bolt on to the inner wings for stability?

 

[Moose McAlpine]

Is the engine support bar home made? Does it bolt on to the inner wings for stability?

No, that's a genuine VW one. It just sits on the inner wings, i sometimes use straps around the bonnet hinges if needed. That one has a number of different legs for different cars.

 

[Bobupndown]

No, that's a genuine VW one. It just sits on the inner wings, i sometimes use straps around the bonnet hinges if needed. That one has a number of different legs for different cars.

Brilliantly simple idea, easy to make one as well (fires up the welder.......)

 

[KemppiFrog]

They're not too bad on the floor. 5-speed is much easier than 6-speed, which is already easy. Both have a dual mass flywheel.

You'll need M8 triple square for the driveshaft bolts, and a 9mm 12-point for the clutch bolts.

If you want to make the job really easy, get an engine support bar and a ratchet chain hoist.

View attachment 421976
View attachment 421977

(That's a 6-speed.)

Useful pics Moose. I can easily fab up the support frame (heck, what forum are we on?) Got several ratchet and chain winches. Bought the point bits when I changed a drive shaft boot for the last test on it.
Unless the flywheel is dicky, I might just swop the plate and spring for new, with the cheaper e-bay options. They are on the edge of wondering how much they need it, verses the money. It actually drives OK and no rust, so a bit spent for a few more years looks like good value.

 

[keithski122]

At a garage I worked at the engine support bar was known as "the godsend" as everytime we used it the service manager would comment what a godsend it was.

 

[KemppiFrog]

Update...
Bits for the clutch arrived ( LuK ), but a bit more here than you lot pay in UK.
Things got a bit more complicated, as their newer Golf was on it's way for the MOT, but hit some farmers muck and fell off the road, write off..
Then, using the older one, as the clutch was OK if you didn't boot it, they went to the local S/mkt just before Christmass, but ran over a curb in the parking lot and smacked the sump, dumping the oil..
I went over with a quickly roughed up solid tow and dragged it back here. New sump arrived today (€47, which I thought was pretty cheap) and should have it all bolted up by Friday.
Just a thought, but what does one look out for on a dual mass flywheel? There were no obvious vibes or other probs.

Obviously I am just helping out friends here. At 76, I really should avoid rolling under cars on cold floors. Should reserve my talents for more fun activaties, like getting my new boat in the water..
KF

 

[Kram]

Things got a bit more complicated

French drivers

I have seen a few French plates doing stupid things over here recently. Wrong side of the road was one but I guess its an easy mistake, when your used to being on the wrong side...

 

[nickk]

Ive realised i drive more miles in France (4-5000m),per year than here,i find their standards are much higher than the uk.