2002 VW Golf refurb

[140mower]

Well, that sucks, however, I have to admit to being emotionally divided....... One side truly feels for you as where you are now is the life I lead, the balls have hit the floor and the transmission is slipping.... On the other hand while you are frantically looking for that last ball some of us (ok maybe them) are starting to look like we are making forward progress.
Our tdi had a dual mass flywheel and when I replaced the clutch I found the center to be quite loose. I replaced it with a single mass flywheel and didn't notice any difference between the two to speak of..... Not sure if the gas ones also have the dual mass....

 

[slow-poke]

How many km are on the odometer?

 

[David]

Well, that sucks, however, I have to admit to being emotionally divided....... One side truly feels for you as where you are now is the life I lead, the balls have hit the floor and the transmission is slipping.... On the other hand while you are frantically looking for that last ball some of us (ok maybe them) are starting to look like we are making forward progress.
Our tdi had a dual mass flywheel and when I replaced the clutch I found the center to be quite loose. I replaced it with a single mass flywheel and didn't notice any difference between the two to speak of..... Not sure if the gas ones also have the dual mass....

This likely has a dual mass but I'll find out tomorrow. It will be a single mass going back in.
@slow-poke 277K on the clock.

 

[slow-poke]

This likely has a dual mass but I'll find out tomorrow. It will be a single mass going back in.
@slow-poke 277K on the clock.

Might be a bit of a hassle fixing the mechanic aspects but I would trade that any day to not have to deal with rust. How typically is that body (rust wise) considering the year and mileage (for a Victoria car)?

 

[David]

Might be a bit of a hassle fixing the mechanic aspects but I would trade that any day to not have to deal with rust. How typically is that body (rust wise) considering the year and mileage (for a Victoria car)?

It's very typical. Vehicles are rust free unless transplanted from another province or from the BC interior where salt is used in the winter.

 

[DPittman]

It's very typical. Vehicles are rust free unless it is a transplant from another provin ince or from the interior where salt is used in the winter.

Not having rust on a vehichle is worth alot in my opinion, most everything else can be repaired relatively easy and restored to like new, rust on the hand is not so easy.

 

[David]

Not having rust on a vehichle is worth alot in my opinion, most everything else can be repaired relatively easy and restored to like new, rust on the hand is not so easy.

In looking at vehicles to purchase, say a Mazda 3 for example, any with rust are immediately off my list, likewise body damage as that's not my skillset.

 

[David]

Didn't have my phone last night when I pulled the transmission.
Here's a couple of pictures.

 

[David]

Ordered this 15 ton hydraulic puller to see if I can get the stuck passenger side axle out.

 

[Susquatch]

Ordered this 15 ton hydraulic puller to see if I can get the stuck passenger side axle out.

Interesting David. I'll. Be curious to know how that works. I have similar pullers in 2 and 3 jaw. I find that even if I oil the center screw, they often load up so badly that you just know that one more turn, will send the whole outfit to the scrap pile. Tightening the screw and then using hydraulics might be just the ticket. Please keep us posted.

 

[David]

Interesting David. I'll. Be curious to know how that works. I have similar pullers in 2 and 3 jaw. I find that even if I oil the center screw, they often load up so badly that you just know that one more turn, will send the whole outfit to the scrap pile. Tightening the screw and then using hydraulics might be just the ticket. Please keep us posted.

I saw it last night in a video where a guy used a 10T version to remove rear axles from a BMW E61 that lived in the NE US so rust was a big factor. Took the press, heat, PB Blaster and a lot of patience.
The video is 41 minutes long and parts are sped up so I expect it took well over an hour or more.

 

[David]

Here's the naked truth.
Pressure plate and friction plate. Friction plate is 5.35mm thick, basically down to the rivits. New one is 8.37mm thick.

Flywheel. Single mass apparently. Makes me think this is the second clutch and I'm installing the third.

 

[slow-poke]

hmmm.....
- It's been a little warm, but at least no heat cracks
- might be cheaper to resurface than replace?
- as badly worn as it is, does not explain no forward motion when in gear?
- I'm curious, diameter of disc?
- Often crankshaft flange holes open to the crankcase so use locktite

 

[David]

New Luk flywheel is only $60. Don't think it's worth the time and effort to try and find a local place that would resurface it.
New Luk pressure plate and friction disk is $220.
There was a tiny bit of movement but not enough to actually roll the car.
Friction disk is 8.5" diameter

 

[FatherWes]

As blue as that flywheel & pressure plate are, I personally wouldn’t be reusing them.
But given how easy they are to access …

 

[Chicken lights]

Does that have a pilot bearing or bushing?

And seconded on blue loctite on everything clutch related, plus torquing to spec

 

[David]

Does that have a pilot bearing or bushing?

And seconded on blue loctite on everything clutch related, plus torquing to spec

I want to say bushing but I have to double check

 

[Chicken lights]

I want to say bushing but I have to double check

I've got a puller if you want to pop over and borrow it. If not a slide hammer with a finger hook can work. Never had luck with the grease trick

 

[David]

I've got a puller if you want to pop over and borrow it. If not a slide hammer with a finger hook can work. Never had luck with the grease trick

Pop over? Aren't you in Ontario???

 

[140mower]

I've got a puller if you want to pop over and borrow it. If not a slide hammer with a finger hook can work. Never had luck with the grease trick

I have had great success with the grease method, ideally the bolt you use should be just smaller than the hole, then a couple wraps of electrical tape. Enough that when you drive it with a hammer the outside wrap or two get scraped off....