Lesson 1Common mistakes to avoid: misalignment, improper torque, contaminated friction surfaces, and inadequate engine supportDodge usual slip-ups that lead to early clutch failure or dangers. Covers disc misalignment, wrong torque, dirty friction bits, and poor engine or 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 checkPrep the flywheel for reuse or swap. Cleaning tips, when to resurface, bolt torque order and values, and measure final runout to VW specs.
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 shieldsTake off bits blocking gearbox access on the Golf/GTI. Safe removal of battery, airbox, intake pipes, crossmembers, heat shields, labelling fixings for easy re-fit.
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 reinstallationRefit all removed parts and check torque on key bolts. Covers crossmember, axles, linkages, heat shields, plus fluid top-up and underbody check before road test.
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 old clutch parts to see what needs replacing. Disc thickness, rivet wear, pressure plate face, flywheel state, release and pilot bearings, 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 up tools and gear before cracking open the drivetrain. Torque wrenches, impacts, trans jack, alignment tools, engine supports 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 bearingFit new clutch kit right way round in proper order. Use alignment tool, torque pressure plate and pilot bearing to spec, check disc moves free on splines.
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 and prep joining faces before new clutch. Degrease flywheel, check crank pilot bore, clean bellhousing inside, brush disc splines.
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 PPESet up safe workspace for FWD VW clutch job. Right jack and stand spots, wheel chocks, battery off, PPE to avoid injury or vehicle harm.
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 specRefit gearbox to engine without forcing. Align input shaft to disc, seat bellhousing on dowels, tighten in order, renew seals and bolts 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 and lift off gearbox safely. Bellhousing bolt spots, starter out, dowel lining, lower gearbox steady without wiring or sensor damage.
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 without harming flywheel or crank. Loosen pressure plate bolts in order, support assembly, handle old bits for check or bin.
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 linkagesHold engine firm and split from gearbox without strain. Engine bar setup, drain oil, remove driveshafts, CVs, mounts, shift links 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
