advice/how to change 5 speed clutch

[marin]

Ok, i am reasonably mechnicaly minded, i'm a fitter by trade, but have never changed a clutch, we have a sachs clutch kit here, any advice, tips etc?

The car is a 1990 golf cabriolet 1.8 5 speed

found this site http://www.vintagewatercooleds.com/t...tch/clutch.htm but any extra info/hints/tips would be good

marin

[h100vw]

M8 spline drive to undo the drive-shafts from the CVs. once everything is undone, you need to rotate the back of the gearbox up so that the right hand drive cup will fit through the gap on the back of the block.

A trolley jack under the sump to drop the engine works good too.

Gavin

[Jmac]

You need special tool to line up the clutch, which you could get from a good tool supplier. Or even better if a VW Mech can lend you it. The clutch is back to front mate with the fly wheel first covering the clutch plate and pressure plate. The special tool is a plastic plate around the size of a small saucer. You will need a M9 multi hex socket 3/8 drive for the pressur plate bolts and most importantly there is a couple of dowel on the flywheel that must go back in the right spot( VERY IMPORTANT) Mate feel free to Pm and you can have the run down mate.
Really not a bad clutch to do.
Jimmymac

[86gti]

You need special tool to line up the clutch, which you could get from a good tool supplier. Or even better if a VW Mech can lend you it. The clutch is back to front mate with the fly wheel first covering the clutch plate and pressure plate. The special tool is a plastic plate around the size of a small saucer. You will need a M9 multi hex socket 3/8 drive for the pressur plate bolts and most importantly there is a couple of dowel on the flywheel that must go back in the right spot( VERY IMPORTANT) Mate feel free to Pm and you can have the run down mate.
Really not a bad clutch to do.
Jimmymac

hehe, always lined it up by eye, involves stuffing your head ip in where the gearbox sits......dont drink too much before you attempt that tho! lol.
got it in first time every time.
...but lining it up with an aligner means you know for shure!!

[marin]

Thanks for that, our kit came with the plastic cup aligning tool thingy, which seems to be a good thing to have from what i have read and what people are saying. Gona attack it on boxing day, that way don't have to worry about having it ready to drive around on chrissy day if anything doesn't go right lol so keep an eye on here on box day for incase it all falls in a heap! (hopefully not)

marin

[Jmac]

Benny you are a crazy horse i drink too much so that method is out for me hehehehe good onya mate, but hey you know what i mean about the dowels? ive seen a couple of sad things happen because they were misaligned.
Like i said Marin go for it with the PM i will have my mobile on me 0423965341 if you get in the brown on boxing day mate. Feel free.
By the way thats great that they supplied the aligner a big plus. What make is the clutch and who supplies it??? back in the day you needed the tool but if they have the heads screwed on now it great man.
Jimmymac

[Golf Loon]

I have never used the aligning tool either, just make sure it is equal all the way round

Take off the brackets on the gearbox if you need extra movement to rotate the gearbox up and out.

You`ll be right.

[marin]

Benny you are a crazy horse i drink too much so that method is out for me hehehehe good onya mate, but hey you know what i mean about the dowels? ive seen a couple of sad things happen because they were misaligned.
Like i said Marin go for it with the PM i will have my mobile on me 0423965341 if you get in the brown on boxing day mate. Feel free.
By the way thats great that they supplied the aligner a big plus. What make is the clutch and who supplies it??? back in the day you needed the tool but if they have the heads screwed on now it great man.
Jimmymac

Thanks for the support there, hopefully won't have to call you, but you never know. It's a sachs clutch kit, g/f's dad sourced it from the US, it's a KF785-2 , hopefully it's the right 1 lol

marin (Ben)

p.s. just found the invoice in the box, it's from eurosport accessories in Anaheim, CA, description says "SACHS SUPER SET 210MM CLUTCH KIT - R/CAB/JI/SI&II - 1.8LTR. 8V"

inc. shipping came to $280 (I presume that is US $, so whatever that converts to atm)

[Bora Sport]

Maybe it has been mentioned elsewhere but if not. When you change the clutch on MK1's you should always replace the brass bush and rubber seal inside the shaft for the clutch actuation lever. Otherwise you run the very real risk of oil seeping along the shaft and ending up spinning up onto your shiny new clutch material and spoiling it for good.

I'm speaking from experience here. Dave DOHC also has had the same experience.

[Valver.]

The spline won't go in if everything isn't aligned anyway A worklamp and a middle finger is just as good!

You should have the flywheel machined, and all the mounting bolts have to be replaced

[marin]

Well, gearbox is out, after much fiddling, and having the box drop onto me just clipping my mouth..... found oil all through the bell housing, and just saw that tip about changing the brass bush and the oil seal, so we think we will do that, but the rear main seems good, so gona leave that for now (yeah, i know, should do it whilst we are there, but we have enough to do as it is).

The old clutch still has life in it, but we gona put the new 1 in anyways, clean up all the oil change the sael and bush, and hopefully get it all back in by 2morrow night! (lol not gona happen, but i like to be optimistic about it!)

marin

[h100vw]

Leave that main seal well alone if it's dry now. No way to test you have done it right, without putting the box back, if it leaks then you'll be well annoyed about it. Having done it myself, I know I am right!!
Gavin

[marin]

OK, so it's mostly back together, all except the drive shafts back on is done, so we started it up and gave it a go, and all seems good except that when in neutral with the clutch out, there is some drive to the wheels, but put the clutch in and no more.... problem is we don't know if it did it before.... any reason to be concerned? Friend of mine said that it might just be some tightness in the box that was there before, or something like that....

marin

[h100vw]

OK, so it's mostly back together, all except the drive shafts back on is done, so we started it up and gave it a go, and all seems good except that when in neutral with the clutch out, there is some drive to the wheels, but put the clutch in and no more.... problem is we don't know if it did it before.... any reason to be concerned? Friend of mine said that it might just be some tightness in the box that was there before, or something like that....

marin

That's normal, it's just drag in the oil. You will be able to hold it with your hand.

Gavin