HELP!!! Im scared - gear box/thrust bearing noise

[Jmac]

Ah ok , my father in law lives in Branyan. Ill be sure to call next time im up there. Anyway, totally here what you are saying with the sandwich method, makes total sense. Ok whats the part number of the kit you bought??? I use a light kit for the VR on the Polo Gtis wit the 02R box, i get that kit from ECS tuning.
Post the number and ill have a look. Problem must be in the kit somewhere, really never have any issues with clutch installs on the AAA mate, and its a rockhard engine too, keep it serviced though
Cheers
Jmac

[courtz1976-2dr]

HI there Jmac,

Kit no for the scahs kit K70038-2, yeah I calleds sachs too and checked the no on the pressure plate - it must be the o2j might be a little different ot the o2a in this case after hearing that they are exactly the same??? (btw am fitting an o2j and I hope that I haven't been misinformed and this is the root cause of all issues!!!!!)

I had a look again at the old and new gearboxes too and this is all fine same "plunge depth" to that part that is clashing on new gearbox. what a wierd scenario. the only thing that I cant tell for sure is the flywheel parts here is the link

GermanAutoParts.com

Final verdict is that there is close to 3mm difference in the OLD oem clutch/pp/flyweel combo than the new sachs kit - I see that with ecs tuning there is a warning on their stage 3 clutch only to use the oem flywheel I wonder if this is the reason!!!

http://www.ecstuning.com/Volkswagen-Golf_III--VR6_12v/Drivetrain/Clutch/ES5863/

Do you think that I have a case for having the parts refunded and maybe my gbox that is now slightly compromised due to this damage???

What a nightmare, all this work done with no hoist and besa blocks and a ****ty little trolley jack!!!

Doing the work tomoz hopefully engine will be back in in a day - got a technique now that I should be able to kill it...Keep you posted

[Jmac]

The 02A clutch housing is the same as the 02J, but having said that the part number differs slightly for 5/6 cylinder vehicles. What did your 02J come out of mate? Ive mixed and matched these on 4 cyl gtis and the likes but havent done it with a 6 mind you. Ive got a AAA in my shed , ill have a look, ive also got a 4 cyl 02R from a Polo, they have the 02J clutch housing, ill see if i can make sense out of it
Jmac

[courtz1976-2dr]

Engines back in YAAAAHOOO and no noise - far out whata mission - started at 10am this morning and engine started at 4pm, still need to stik the front end back on but pah thats the easy stuff oh and driveshafts. Just thought I would let you know - there must be enough clearance for the sachs kit with original flywheel but not the lightened extra 1mm or so but even so I wasn't willing to take the risk so Luk (may the force be with it) went back in. If I ever plan on "upgrading" anything in the future I will be very wary. like they say assumption is the mother of all ^%&*ups.

So anyone interested in a lightened flywheel and sachs pressure plate I dont like my chances.