Gearbox removal

[davlin]

Hi Folks,
Recently I have been having problems with speed(Don't we all). I use to be alble to drive along at 40mph in 5th gear, but over the past few weeks the car has started to shutter and had to drop down into a lower gear (4th and sometimes into 3rd). This morning when in a traffic jam there was vibration in the clutch pedal (this has been going on for a while now) and I could hear 'tinking' noices from the engine bay. Is my clutch about to give up? I believe it has a Dual Mass flywheel is this the problem? If so is it hard to remove the gear box or can you direct me to the thread that shows me. I have a reasonable knowledge of mechcanics thanks to the forum of the Passat.
I have a 2004 VW Passat, 96KW, TDI, 211000 miles (original Clutch) AWX.

Many Thanks
Davlin

[Doctle Odd]

Hi Davlin. Have you access to a ramp or lift? If not its a pig of a job takes forever and is a bit dangerous, you'd be under the car a lot. If you are doing it on the ground use a hoist and just pull the engine out change the clutch and back on again. Allow 4-6 hours. It's easier than loosening the driveshafts suspension etc and you won't need the tracking done afterwards. It's just bolt off/bolt on. Change your coolant if it's been in more than 2 years and if the belt needs done you have super easy access

[caldirun]

Hi Davlin. Have you access to a ramp or lift? If not its a pig of a job takes forever and is a bit dangerous, you'd be under the car a lot. If you are doing it on the ground use a hoist and just pull the engine out change the clutch and back on again. Allow 4-6 hours. It's easier than loosening the driveshafts suspension etc and you won't need the tracking done afterwards. It's just bolt off/bolt on. Change your coolant if it's been in more than 2 years and if the belt needs done you have super easy access

I changed the wife's DMF on a AVB engined Passat last year, just bought a good jack and put it on axle stands, no suspension was disturbed and only inner drive shaft couplings were released, a fair bit of work but no engine hoist required!

[Doctle Odd]

I changed the wife's DMF on a AVB engined Passat last year, just bought a good jack and put it on axle stands, no suspension was disturbed and only inner drive shaft couplings were released, a fair bit of work but no engine hoist required!

It's horrible getting the box back in, lying on a driveway with gravel embedding itself into your spine. years ago I put a clutch into a Mini at dusk. My brother was holding the light so he could see rather that me. I could have wept hateful job on a hateful damp dark evening. Passat isn't that bed!

[davlin]

I changed the wife's DMF on a AVB engined Passat last year, just bought a good jack and put it on axle stands, no suspension was disturbed and only inner drive shaft couplings were released, a fair bit of work but no engine hoist required!

Thanks folks for all your help. I dread the thought of disconnecting all the wiring and pipes to take the engine out, and I presume that I have to take the front of the car away to gain access? I have done this before to change the radiator and although it went smoothly it did take a long time.
Caldrin, I am assuming that you get the car as high as you can with the axel stands and lower the gearbox as much as you can to seperate it from the engine, and the engine is still in the car. Is there any tips you can give in seperating the gearbox fromthe engine, and is there anything special about this DMF? is removing and replacing it awkward? do I have to get new bolts. I was loking in EuroParts and they sell them seperatly for about £7.

Davlin.

[davlin]

Hi Doctle Odd,
Thanks for your reply, As I stated in Caldirun's Message that I sent, I am unsure about disconnecting all the pipes and wiring looms to remove the engine, I dont have a ramp or hoist to lift an engine out. Just good axle stands. I'm more confident of doing in line gearboxs. Manys a day and night like yourself I have lay for many hours taking the gearbox out of an Escort, Capri and Cortina's lying on inches of snow and relying on the guy holding the rope through the gearstick housing not to let go. I was younger then and this would be my first transversal engine that I would be doing so you can realise my aprehension. I just cant afford the cost at the moment of putting it in a garage to replace it.

Many Thanks
Davlin.

[Doctle Odd]

Ho Davllin, You can get the gearbox out from underneath the car it's awkward tho. Putting it back is the hardest part as you're lifting it forward, upwards and aligning it whilst lying in a confined space with a heavy gearbox inches from your head. Of course it can be done, a transmission trolley jack would be a godsend for that job. The actual fitting of the flywheel and clutch is very straightforward. Removing the engine in these cars is very easy, not many pipes really, fuel and coolant is about all there is. Tie up the aircon pump. The wiring plugs only fit in their respective connections. Clutch replacement Passat tdi

[caldirun]

I have 2 Passat tdi's neither have a transverse engine, not sure what you have!
I must emphasise, GET A GOOD JACK, I bought a beauty for only £80 with 2 tonne, 500mm lift and used axle stands (you need as much height as you can safely get) the high lift jack came in for getting the box back in, not easy as stated but a 59 year old did it, not lying in snow or gravel (when you are older you use your brain and put a rubber mat down)
I used a kit from Euro Car Parts, bolts were included, I knocked an alignment tool up for the driven plate and did not change the needle bearing as it was still greased, clean and as smooth as silk and a b.....d to remove. Worst thing I can remember was getting the stupid lug on the gearbox past the sodding exhaust, next time I will disc the stupid thing off first.

Hi Doctle Odd,
Thanks for your reply, As I stated in Caldirun's Message that I sent, I am unsure about disconnecting all the pipes and wiring looms to remove the engine, I dont have a ramp or hoist to lift an engine out. Just good axle stands. I'm more confident of doing in line gearboxs. Manys a day and night like yourself I have lay for many hours taking the gearbox out of an Escort, Capri and Cortina's lying on inches of snow and relying on the guy holding the rope through the gearstick housing not to let go. I was younger then and this would be my first transversal engine that I would be doing so you can realise my aprehension. I just cant afford the cost at the moment of putting it in a garage to replace it.

Many Thanks
Davlin.

[Doctle Odd]

I have 2 Passat tdi's neither have a transverse engine, not sure what you have!
I must emphasise, GET A GOOD JACK, I bought a beauty for only £80 with 2 tonne, 500mm lift and used axle stands (you need as much height as you can safely get) the high lift jack came in for getting the box back in, not easy as stated but a 59 year old did it, not lying in snow or gravel (when you are older you use your brain and put a rubber mat down)
I used a kit from Euro Car Parts, bolts were included, I knocked an alignment tool up for the driven plate and did not change the needle bearing as it was still greased, clean and as smooth as silk and a b.....d to remove. Worst thing I can remember was getting the stupid lug on the gearbox past the sodding exhaust, next time I will disc the stupid thing off first.

I gave up lying on gravel a long time ago too. A sheet of marine ply makes moving the jack a lot easier. I'm a little younger than you Caldirun and if I ever have to do another I like the look of this http://www.ebay.co.uk/itm/Sealey-Too...item2ed4dc1d01

[caldirun]

I gave up lying on gravel a long time ago too. A sheet of marine ply makes moving the jack a lot easier. I'm a little younger than you Caldirun and if I ever have to do another I like the look of this Sorry, that's not working right now

Looks handy but I only had 2 axle stands on the front so the 5' adjustment would be insufficient, better to cut a chunk of wood for the cradle on your high lift jack, then you can get the angle correct