Clutch Change Guide

[liam_0404]

Hi,

Going to attempt a clutch change on my 1.6 GT, has anyone got a guide or any tips for this as it'll be my first time changing the clutch etc.

Thanks, Liam.

[steve bain]

the gearbox is heavier than you think. but can be lifted / manhandled with the help of a jack
buy a torque wrench and use it.
buy a clutch allignment tool.
don't forget to disconnect the speedo!
buy a bush kit for your gear link as you might as well do it whilst your there.
make sure you have the right tool for the driveshafts. its a multi spline jobby.
you'll probably need to pop the pass side wishbone to get enough space between driveshaft and drive flange.
support the engine from beneath when you remove the gearbox mount when you remove the starter the front mount is no longer connected so it will fall!
good luck

[mark1gls]

Agree with Steve, I found It's getting the gearbox back on to the spline which can be a pain if it does not line up it can be a fiddle if lying on your back and holding a gearbox.
Last time I did it I had the engine out so no radiator or fuel injection stuff in the way so I could stand over the top of the gearbox and lift it up and on as you have to also get the drive shafts into the cups/flanges as I found you can get them out or in to the cup/flanges with them in place.

[liam_0404]

I assume the multi spline is one of those 12 star ones? (if that makes sense) Do you know what size? I have a kit of them somewhere.
Looks like I'll need 2 jacks to make it easier, should have a pair of hands to help out too so might help with aligning. I have the VW alignment tool, torque wrench, Heinz manual etc.
I'll have a look at getting some bushes then, is it worth replacing anything else (driveshaft bolts, CV boots)? I have gearbox oil to go in after I've changed it all.
Sorry about the questions, I'd like to have a go at changing it myself as I've managed to do everything else so far!
Liam.

[mark1gls]

Put the car up on axle stands then it will free up your trolly jacks but you still need 1 for the engine and possibly 1 for the gearbox is needed.

Yes it's a 12 star type, I'll check the size for you.

Don't worry about CV boots unless old, It may be worth getting some plastic carrier bags to place over the inner CV boots when you remove the gearbox to stop and dirt etc getting into the grease.

I would post up some pictures but Photo bucket has blocked my account as it's full (been like it for about a year) but they are not letting me in to delete some photos and I'm not paying them money..

[liam_0404]

I have one trolley jack and shouldn't be an issue to find another.
Luckily as it's not a daily I can leave things if I need parts or advice, might give it a go next weekend if the weather is good.
You might be able to just attach the photos straight on here.

[james butler]

get yourself a peice of (i think) m10 threaded bar about 6 inches long and screw into one of the holes that bolt the top of the gearbox to the block.
this will aid getting it on and around the flywheel and other bits.
once clear of the flywheel yo can drop it down and out.
it makes it a lot easier to slide the gearbox back into position when putting it back in as the bolt hole in the gearbox will line up easier if guided into place with the threaded bar.

[scrappy1382]

the gearbox is heavier than you think. but can be lifted / manhandled with the help of a jack
buy a torque wrench and use it.
buy a clutch allignment tool.
don't forget to disconnect the speedo!
buy a bush kit for your gear link as you might as well do it whilst your there.
make sure you have the right tool for the driveshafts. its a multi spline jobby.
you'll probably need to pop the pass side wishbone to get enough space between driveshaft and drive flange.
support the engine from beneath when you remove the gearbox mount when you remove the starter the front mount is no longer connected so it will fall!
good luck

driveshaft tool needed is an M8 spline. not a T40 like some believe