ABF/ KR/ 2Y Clutch Slippage

[rubjonny]

also when box is off make sure input shaft seal & pushrod bush & seal are done, if any o that is worn you can get box oil all over your shiny new clutch. may be what has happened here. oem sachs clutch is good gear, plus its a complete kit with everythign you need, new pp bolts, spline grease etc.  before you buy anything, get underneath and check the gearbox code, no telling if its the original

[Neo Badness]

also when box is off make sure input shaft seal & pushrod bush & seal are done, if any o that is worn you can get box oil all over your shiny new clutch. may be what has happened here. oem sachs clutch is good gear, plus its a complete kit with everythign you need, new pp bolts, spline grease etc.  before you buy anything, get underneath and check the gearbox code, no telling if its the original

Cheers for reply RJ
Yeah was thinking OEM clutch as I've been trying to replace all the sh!te with vw parts to get some reliabilty back into the car and keeping the "good" aftermarket bits konis etc.
G/box code should be 2Y but this is stamped on the underside(?) Will price an OEM clutch kit from VW, expensive I imagine but, I get a 15% discount so might be worth while.

[rubjonny]

yeah if you look on bottom o gearbox theres a flat plate, thats where the box code and date of manufacture are stamped

[Neo Badness]

Cool will get on it, it's a bit of a mission getting a jack under it as it's so low at the mo, but i have a plan.

As someone who's changed a few clutches, is it easy enough to do yourself?

I was looking for a how to but didn't find it.

[rubjonny]

its not particularly hard, just box is heavy and space is tight. apart from the obvious bits to unbolt, what you do is rotate the box so the diff is pointing straight up, then drop it out from underneath.  I found it helped to lower the engine at the gearbox end while its still bolted up, then unbolt the 2 brackets from the box before trying to remove it from the engine. Oh and dont forget the tin shield underneath between box & sump, and the other one round the back just above the driver side driveshaft

tip for reassembly, get the driveshafts in position as soon as you can, if you arn't careful they end up trapped below the box and they wont go back into place! alternatively you can unbolt the balljoints from the bearing carriers and then you can swing the struts out a bit to give you room to faff with the shafts.

[Neo Badness]

Cheers RJ, I've printed that reply to refer to

for aligning the clutch, any trick to it or just a case of rebolting it as it was when opened the box? Assuming it was done right first time
You don't need to remove the box completely you just need to jiggle it apart (technical term) to get access to get the clutch/ pressure plate etc out?

I've been speaking to my friend of a friend who has just completed his new garage, it's got an inspection pit! Hopefully get in there to do the work. Will take photo's as I go I think.

[rubjonny]

clubgti has a good faq post on thise, really helps. prob wont be able to leave box in, not much room! with clutch aligning, its enough to do it by eye. as long as its close enough to allow you to bolt the box on, its all good, as soon as you press the clutch pedal it'll self-centre anyway.

oh and a trick from broke on getting pressure plate bolts out, I use a similar method but rather than using a flywheel bolt I found a suitable casting on the PP to hook the spanner onto:

[Neo Badness]

Cheers RJ, interesting stuff.
Been geeking out over Broke vw for past few hours. Will have a look at the FAQ tomorrow night when I get a min.

Thinking about lashing the cash to get this http://www.madmotors.co.uk/catalog/black-clutch-golf-8392-p-16836.html anyone any experience?

Will continue you with research and getting this garage organised, roll on the brighter evenings so I can get more done

[rubjonny]

ouchie, is your engine quite uprated then? I just have boggo sachs kit on mine and it works great. but then, it is std!

[Neo Badness]

ouchie, is your engine quite uprated then? I just have boggo sachs kit on mine and it works great. but then, it is std!

I dunno, I've never had it running 100% to find out  Don't think it's got anything other than std power. 4 branch, home ported/knifed t/b, 140hp maybe? Tried to source a OEM sachs kit but obsolete from dealers as of Dec 09 Haven't spoken to my motofactor yet though, will do that lunchtime.
Pet hate is a slippy clutch so might take a belt and braces approach if it means I don't need to replace it for 50-70k and it gets a fair amount of abuse.
Will be changing my g/box fluid at the same time... Cause the fun never stops with 20yr old cars