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Aaaarrrrrrggghhhh...



The A3 trannies - CHE, DFQ, etc. are like a 16v tranny in that they have the
big input shaft.  So you will need to use a 16v clutch disc (same as A3
disc).

Jeff
----- Original Message -----
From: "Mark F." <mardak@gmail.com>
To: "Scirocco List" <scirocco-l@scirocco.org>
Sent: Thursday, February 23, 2006 10:13 PM
Subject: Aaaarrrrrrggghhhh...


I noticed yesterday that my clutch was slipping a bit when I "dropped"
the clutch in 4th or 5th - the first signs that the end is near...
Since I'm heading to Baltimore this weekend to dolly home Mark Peele's
82 I thought it'd be a good idea to swap out the clutch.  So today
Sean and I rented a hoist a semi-local DIY garage to make quick work
of clutch job #1044 of my DIY VW career.  I had a brand new pressure
plate and clutch disc on the shelf anyways, as well as a complete
tranny/clutch swap "kit" I bought at Waterfest (all bolts, seals,
etc.), so what the hell...

Everything came apart fine, with no rusted/seized bolts, and we had
the tranny out (and both lower control arms/spindles to be swapped) in
an hour.  It turned out the engine rear main seal was seeping a bit of
oil, and had oiled-down the clutch (which still had about 1/2 it's
life left).

Things took a turn for the worse when we went to put everything back
together.  The first sign of trouble was the dowel on the flywheel
wasn't fitting in the slot on the new pressure plate.  Even liberal
use of a BFH yielded only more frustration.  So, off came the freshly
installed pressure plate, to be replaced by the used (still good) one
I just removed.  Had it all torqued up, and flywheel bolted to it,
before realizing I forgot to install the pushrod plate dealie...
F**K!!!  So, off came the flywheel.  Put the mess all together AGAIN,
and prepped the tranny to reinstall...

Not realizing the shop actually had hydraulic tranny lifts Sean and I
struggled with the tranny, trying till our arms were about to fall off
to get that fucker seated.  It just wouldn't slide home - even after
spinning the shaft a bit in case the splines weren't meshing...  I
then splotted the lift, and we tried again.  After much cursing it
still wouldn't go, so I figured something wasn't right...

It turns out the 210 mm clutch disc I had on the shelf was for a
smaller splined shaft tranny...  I assumed that all 210mm 020 8v discs
were the same, but I guess I was wrong...  The tranny is a DFQ 020
from a 98 Jetta.  Anyone confirm this for me?  (I don't have ETKA
installed on this computer)...

So, since I was paying $12/hour for the hoist, and the
dealership/flaps were no longer open I was forced to put everything
back together again the way I drove it into the shop.  I changed the
rear main seal, and used a bunch of brake cleaner to try and "de-oil"
the clutch disc, and reassembled the works...  The clutch still slips,
even after a long drive with several clutch-slip heat cycles.  SO, I
now have to do the whole thing over again tomorrow...  We're going to
see how fast we can do the job...  Who's got the time to beat?  :)

Later,

Mark - greasy and pissed...
75
86

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