I'm making a DIY for Fourtitude/Vortex Forums on clutch and flywheel replacement on a B5 A4.
Here's the pics.
Torque specs:
Flywheel Bolts: 44ft lbs + 90 degrees
Pressure plate bolts: 16 Ft lbs(A4), 18 ft lbs (Passat). I did 18ft/lbs.
Rear Drive shaft bolts: 26ft/lbs
Hardware required. This is a picture of OEM replacement hardware. Anything I'm using in the following photos may be different as I am not doing an OEM replacement clutch/FW install.
Tools required include an array of 3/8" and 1/2" sockets & extensions (10mm, 13mm, 15mm, 16mm, 17mm, 19mm, 6mm Hex/allen, 8mm Allen, swivel, couple 6" ext. and one 3"), a set of "triple square" sockets, transmission jack(to save your ass), Jack stands, Jack, probably a helper, pry bars, 16mm combination wrench, and maybe a couple others.
#1 Properly Support vehicle on jack stands, remove front wheels and exhaust heat shield over the right CV
#2 I removed the right side trans mount because I removed my exhaust in one piece.
#3 Remove rear driveshaft and heat shield. Book says the drive shaft bolts are one time use only, you SHOULD replace them.
transmission output should look like this
#4 Disconnect electrical connections and shift linkage. The two rods you need to disconnect from the inside and the one if you want to off the transmission. I did this before I disassembled the front CV's to help prevent getting filthy. You can see the bolts are loose already, they are a "triple square" head bolts. You can see that later I took the CV's and covered them with plastic bags to help keep them clean.
#5 Begin removal of transmission/bellhousing bolts. Here's my trick to getting these lower three bolts. One of the pics you can see the CV covered w/ a plastic bag.
Now is a good time to remove the slave cylinder from the transmission. there should only be one bolt holding it on, be careful though, it's plastic so don't pry hard on it to get it out. I got mine out by hand twisting it slightly, just be careful.
#6 remove transmission and replace the goods.
Old pressure plate, clutch and flywheel. Good time to replace the throw out bearing, as well as the pilot bearing.
Be careful when removing the transmission there's some heate core lines at the top of the trans that get in the way, as well as some starter wires. This goes for install as well, pinching wires is NOT good.
Install new parts. Make sure the release arm is attached by the clip and the release bearing is snapped into place.
If you have not already, draining the transmission is a good idea. You'll need one of these...
I picked mine up from ECS Tuning, made by Schwaben and it's $28 + S/H
What not to do with O-rings.
I'm having issues, and I'm using this site to host the pics.
