Lesson 1Common mistakes to avoid: misalignment, improper torque, contaminated friction surfaces, and inadequate engine supportNo do common mistake wey cause early clutch fail or danger. Ting like disc wrong line, bad torque, dirt on friction, poor engine gearbox support.
Recognizing disc and hub misalignmentConsequences of incorrect torque valuesPreventing oil and grease contaminationAvoiding damage from poor supportPost-repair checks for noise and judderLesson 2Flywheel service: resurfacing instructions, torque sequence and final runout checkReady flywheel for use or new. Learn clean way, when resurface ok, torque order value bolt, measure final runout to VW spec.
Cleaning flywheel and crank flangeResurfacing limits for dual-mass unitsFlywheel bolt torque and angle sequenceUsing threadlocker where specifiedMeasuring and interpreting flywheel runoutLesson 3Removing ancillary components: airbox, intake piping, battery, cross-members and heat shieldsRemove ting block transmission on Golf/GTI. Learn safe take battery, airbox, intake pipe, crossmember, heat shield, label hardware for easy put back.
Battery, tray, and ECU bracket removalAirbox and intake piping removal stepsHeat shield and undertray removalFront crossmember and brace removalLabeling fasteners and clip locationsLesson 4Reassembly of removed components and torque checks: crossmember, axles, linkages, and heat shield reinstallationPut back all remove part, check torque on big fastener. Cover crossmember, axle, linkage, heat shield put, final fluid fill, underbody check before road.
Reinstalling subframe and crossmembersRefitting axles and torquing axle nutsReattaching shifter cables and bracketsReinstalling shields, trays, and intakeRefilling gearbox oil and leak checksLesson 5Inspection protocol for removed parts: disc thickness, rivet wear, pressure plate mount face, flywheel surface and bearing checksCheck all remove clutch part decide weh need new. Disc thick, rivet show, pressure plate face, flywheel, release bearing, pilot bearing, fork wear.
Measuring disc thickness and rivet depthChecking pressure plate face and springsAssessing flywheel surface and hot spotsInspecting release and pilot bearingsExamining fork, pivot, and guide tubeLesson 6Tools and special equipment setup: impact wrenches, torque wrench, transmission jack, clutch alignment tool, engine supportSet all tool special ting before open drivetrain. Cover torque wrench, impact tool, transmission jack, clutch align tool, engine support for Golf/GTI.
Selecting metric hand tools and socketsUsing impact tools without damageTorque wrench ranges and calibrationSetting up transmission jack safelyEngine support bar and sling optionsLesson 7Installing new clutch components: fitment order, use of alignment tool, torque specifications for pressure plate and pilot bearingPut new clutch kit right order way. Use align tool, follow torque for pressure plate pilot bearing, check disc free move on input spline.
Confirming correct replacement partsOrienting disc and pressure plate marksUsing clutch alignment tool accuratelyTorquing pressure plate bolts in stagesInstalling pilot and release bearingsLesson 8Preparing mating surfaces: flywheel cleaning, checking pilot bore, cleaning bellhousing and clutch splinesClean ready all join surface before new clutch. Degrease flywheel, check crank pilot bore, clean bellhousing inside, brush clutch disc spline.
Degreasing flywheel and pressure plateInspecting and cleaning crank pilot boreCleaning bellhousing dust and oilBrushing and lubricating clutch splinesProtecting friction surfaces from greaseLesson 9Preparation and safety: workspace layout, jack and stands points, wheel chocks, battery disconnect and PPEMake safe good space for FWD VW clutch. Learn right jack stand place, wheel chock, battery off, PPE stop injury vehicle damage.
Plan workspace layout and lightingCorrect jack and jack-stand positionsWheel chock placement and parking brake useBattery disconnect and airbag precautionsRequired PPE and safe lifting habitsLesson 10Reinstalling transmission: aligning input shaft, tightening sequence, replacing seals and fasteners to specPut transmission back engine no force. Align input shaft clutch disc, seat bellhousing dowel, tight order, new seal hardware to spec.
Aligning transmission and engine dowelsGuiding input shaft through clutch discDrawing bellhousing flush without pryingTorque sequence for bellhousing boltsReplacing seals and stretch bolts to specLesson 11Transmission unbolt and removal: bellhousing bolts, starter removal, careful gearbox lowering and common pitfallsUnbolt remove transmission safe. Detail bellhousing bolt place, starter off, dowel align, lower gearbox control no damage wire sensor.
Identifying bellhousing bolt locationsStarter motor removal and wiring careSeparating bellhousing from dowel pinsLowering gearbox on transmission jackAvoiding strain on harnesses and hosesLesson 12Clutch assembly removal: loosening pressure plate bolts, safe support of flywheel/pressure plate, and disposal of old partsRemove clutch no damage flywheel crank. Learn right order loose pressure plate bolt, support assembly, handle old part check or throw.
Marking clutch orientation before removalLoosening pressure plate bolts evenlySafely supporting pressure plate and discRemoving and handling dual-mass flywheelBagging and labeling old parts for reviewLesson 13Supporting engine and separating transmission: engine support methods, drain gearbox oil, remove driveshafts/CV joints and linkagesSupport engine good separate transmission no stress mount. Learn engine bar set, drain gearbox oil, remove driveshaft CV joint mount shift link on 2.0 TDI FWD.
Positioning and securing engine support barDraining gearbox oil and disposing safelyRemoving driveshafts and CV jointsDisconnecting shifter cables and bracketsUnbolting transmission mounts and braces
