Pulling transmission

[jetta06hbg]

(1) With a lot of gentle persuasion, it is out.

(2) The throwout bearing looks banged up.

(3) The shaft looks really oily - any concerns on this?

(4) The shift lever seal looks fouled.

[jetta06hbg]

(1) The interior of the bellhousing has a lot of oil grime - any concerns?

(2) Evidence of rodentia food mess.

(3) Clutch cylinder - should it be replaced?

(4) Apparent bushing wearing.

[jetta06hbg]

(1) The view of the clutch.

(2) Close up of the clutch. The wear mark appears to be off center - any concerns?

(3) Sachs stamping.

(4) The view of the starter.

[jarrington]

At the risk of succumbing to "While you're in there-itis" I would definitely recommend pulling the clutch and flywheel and replacing the rear main seal. That's the most likely culprit for all the oil and grime. That way you can take the flywheel to be resurfaced at a machine shop at the same time.

-Jason

[jetta06hbg]

Quote:

Originally Posted by jarrington At the risk of succumbing to "While you're in there-itis" I would definitely recommend pulling the clutch and flywheel and replacing the rear main seal. That's the most likely culprit for all the oil and grime. That way you can take the flywheel to be resurfaced at a machine shop at the same time. -Jason

[gadwhite]

If I were you I would replace the following at a minimum.( including your sachs clutch)

1) Throwout Bearing if it dosn't come with it.

2). Slave Cyl because its really easy to do right now.

3). Flex line connector.

4). Trans support bushing (regular if you want quiet comofort, Poly if you want a little stiffer , slightly noisier ride.)

[jetta06hbg]

Quote:

Originally Posted by gadwhite If I were you I would replace the following at a minimum.( including your sachs clutch) 1) Throwout Bearing if it dosn't come with it. 2). Slave Cyl because its really easy to do right now. 3). Flex line connector. 4). Trans support bushing (regular if you want quiet comofort, Poly if you want a little stiffer , slightly noisier ride.)

[jetta06hbg]

(1) clutch disc - it was worn down to the screw heads - any comments?

(2) clutch pressure plate - any comments?

(3) worn pilot bushing - I pulled it out effortlessly without any tools - any concern about this?

(4) back of flywheel

(5) other side of clutch disc

[jetta06hbg]

Is there any significance as to the paint on the fly wheel bolts?


(1) view of the flywheel

(2) closeup of flywheel with evidence oil and grime particles - a lot of which fell out as the clutch assembly was removed

(3) another view of the flywheel with some blueing shown

(4) clean bellhousing

[Tom McKay]

I would think the flywheel needs resurfaced or replaced. It only goes on one way because of the L-tronic sensors. Also you may consider replacing the bolts as my flywheel sheared off the original bolts and I noticed they sell the new set so they must stress out. Great work and pics. Check out International Auto Parts for the new bolt kit and don't forget to mark the flywheel so it gets back on correctly. Take your time and enjoy. Nothing matches wrenching on an Alfa
Tom

[Tifosi]

He's got Motronic, not L-jet, so flywheel orientation is a moot point. (even from a balance aspect if the flywheel gets resurfaced)


My guess on the paint is that they got marked after they were torqued to give a visual indicator that they indeed actually had been torqued and not just snugged in by hand.

[jetta06hbg]

Ok! I think I may have resurfaced the flywheel. It measures within spec. I used the 2" Sanding Disc Kit from HF, specifically the 60 grit disc followed by the coarse "scotch brite" disc. I tried my best to keep the disc true to the working surface and to resurface both the resting and working surface as equally as possible.

Please post any concerns about the condition of the flywheel. I plan to attach the clutch assembly tomorrow night.




Thanks,
Joe

[gadwhite]

Joe
Thats all I did with mine. I figured that since I did not see any damage ( cracks or excessive wear) I would be OK if I just broke the glaze. Yours looked a little more heat spoted than mine , but not much more, and it could just have been the lighting. So far ( 500 miles) I have not had any problems. I sure beats trying to pull the flywheel.

Gabriel

[jetta06hbg]

Removing the front transmission seal reminds me of the axiom of the cheaper the part, the harder to install. Trotting out with the big screwdriver as pictured in the shop manual is not the way to start out.

Instead, start with a flat jewelers screwdriver and work your way up to the larger screwdriver. I used a hammer to power the flat screwdriver as a lever. Once you have the portion of the seal somewhat lifted opposite the notch, you will have to migrate out of the notch to pry out the seal. Work evenly on "both" sides until you get to the point opposite the notch.

Outside the notch, do not use the ring as a fulcrum without some sort of padded protection. I used a wadded up paper towel.

In starting out, I blemished the seat for the seal. But as long as the walls are not impaired, I don't believe that will matter.

Pictures will follow. I am not going to have the transmission rebuilt at this time. So, I will just install the new front seal and reverse light switch before reinstalling the transmission.

Joe

[Tifosi]

..... or you coulda just unbolted the bell housing from the trans body and whacked the seal out with a drift and reinstalled on the bench.....