BKD Clutch and DMF Change

[dk92]

395263952739528

After some swearing trying to get the drive shaft coupling attached to the gearbox on the drivers side off, I changed the clutch on my BKD engine. 208k miles and I believe it is the original from factory. I was getting some clutch slip under heavy acceleration. Pressure plate doesn't look fantastic, but I expected more wear on the clutch its self?

[dk92]

Have a slight problem...

So the Car won't move when the engine is on and I try to engage the gears, just makes a horrible noise. Lifted the car on axle stands to see if drive shaft was at fault but wheels spin as you'd expect in 1st gear/reverse.
Car also moves in 1st gear backwards when the engine/handbrake are off..
Any suggestions?

[Crasher]

What is the VIN and the make/part number of the kit you fitted? Did you fit a new concentric release bearing and does the pedal action feel correct?

[dk92]

2290 601 009 Sachs

Fitted a new Slave cylinder, yes. Pedal feels spongy, no matter how much I bleed. There's a little resistance but not loads.

[dk92]

What is the VIN and the make/part number of the kit you fitted? Did you fit a new concentric release bearing and does the pedal action feel correct?

Sorry don't have the vin to hand, it's a BKD 2007 16v 2.0 TDI.

[dk92]

Update: Took the gear box off - The clutch plate fits the shaft.

Somethings rubbed against the inside of the gearbox slightly and has Caught it (see pic)39530


The pressure plate is correct 39531

Flyhweel also correct? 39532

[Crasher]

Pm me the reg, I can’t check the Sachs numbers until the morning as there is something wrong with my password after a systems upgrade, quelle surprise!

[dk92]

https://uploads.tapatalk-cdn.com/20240915/c2058cff8e754bad63b5d6b0fb8499be.jpg
https://uploads.tapatalk-cdn.com/20240915/3e32fd1a283218ec20ca1d6880190321.jpg
Also noticed this pin is moveable on the plate, surely that’s defective?

Have PM’d you mate. Thanks.

[Crasher]

Is it labelled as a Sachs “EXTEND” system? I can dig deeper when I get Tec Doc working again.

[dk92]

Is it labelled as a Sachs “EXTEND” system? I can dig deeper when I get Tec Doc working again.

https://uploads.tapatalk-cdn.com/20240915/f2266216bdf2189975a06bbfe8ed77b4.jpg

That’s all it’s got on the box

[Whippy53]

I've got that as the 'extend'.

[dk92]

When I put the part number for the package 2290601009 in, it says it doesn’t fit a VW MK5 2.0 TDI 16V according to GSF parts

However the site I bought it off, parts in motion says it does fit my vehicle and is specific for the Mk5 2.0 TDI 16v, as does auto doc. Strange.

[dk92]

An update: I took the hit and purchased an LUK kit and fitted it, works a treat. Completed a drive form Cornwall to Liverpool and it didn’t fall off.

Gonna try and get my money back for the Sachs kit, I followed the exact same procedure for the LUK one and had no issues.

Thanks for those who replied.

[Crasher]

The Sachs Extend has a thicker pressure plate frame and can rub on the gearbox, the solution is a bit of a bodge but you fit an additional engine backplate 038 103 648 H (£15.96) to add less than a millimeter of additional space. Kit 2290 601 009 is the correct one for your car.