Golf GTI 20V non turbo clutch change

[Bill Badger]

Is changing the clutch on a 1.8 20V non turbo Golf easy enough to do at home? I'm on a tight budget and generally do my own work on my cars but I'm concerned about not being able to get it back in again afterwards.

I have good ramps and stands, plus a couple of hydraulic jacks, and to hold the engine up when I take the box out I have an engine hoist. Will this be ok or will I need to get the car higher (ie on a lift)? I don't have facilities to get the car higher than what the stands will allow.

Car has done 150K, so can't complain. AGN Engine is sweet although lacking in power since car is heavy and has no turbo. I will only be fitting a Europarts or similar clutch, so nothing special.

Just out of interest, what is actually meant by 'Remanufactured'? I have seen other clutches advertised with this description and assume they have new friction materials and thrust bearing, but used and cleaned up other parts. Are they ok?

Comments welcome.

[Bill Badger]

Come on folks, surely someone out there has tackled this.........?

[imortalmonkey]

Come on folks, surely someone out there has tackled this.........?

Your box is probably the same as my 1.9 tdi golf 4 as I used an o2j from a 20valve turbo to replace mine,it took me 5 hours to complete the gearbox,clucth and flyweel replacement (dual mass had shifted and started breaking up!!

I worked with tools much like yours,didnt have a hoist but wish i had had hired one due the the weight of the box,

Things to look out for are as follows:

If you dont often do this kind of job get a haynes.

the driveshafts can be unbolted at the gearbox but are fiddley especialy upon refitting when it comes to lining up that first bolt!

Its a heavy box and is awkward to drop down as it gets caught on the steering rack,bit of a pig to restle past this and again when it comes to refitting.

Tee hoist is your best friend with this job,your will need torx bits for the drive shafts and a nice pry bar is handy.

Pay particular attention to the flywheel condition if its a dual mass.

[Bill Badger]

Thanks for your comments. I want to do it really, but just asking in case there is a problem that shows up that could leave me stranded!

My car is a 1999 model without a turbo, and although the gearbox, according to Haynes, is an 02J, I don't believe the flywheel is the dual mass type. I just hope that the clutch hasn't got bad enough for the rivets to cause damage to the flywheel. However, until it's off the car, I won't know.......

Just in case anyone reading this is looking at buying a clutch with a view to doing it themselves, don't automatically assume that if it's on Ebay it will be the cheapest. Europarts offer a reasonable clutch for just under £50. (But if you buy one, get something else to take it just over £50.00 so that you get free delivery!).

[imortalmonkey]

Thanks for your comments. I want to do it really, but just asking in case there is a problem that shows up that could leave me stranded!

My car is a 1999 model without a turbo, and although the gearbox, according to Haynes, is an 02J, I don't believe the flywheel is the dual mass type. I just hope that the clutch hasn't got bad enough for the rivets to cause damage to the flywheel. However, until it's off the car, I won't know.......

Just in case anyone reading this is looking at buying a clutch with a view to doing it themselves, don't automatically assume that if it's on Ebay it will be the cheapest. Europarts offer a reasonable clutch for just under £50. (But if you buy one, get something else to take it just over £50.00 so that you get free delivery!).


Presumably the clutch is slipping? yeah i think your right that the 2.0 petrol doesnt have a dual mass flywheel,Im new to golfs but mines had so much wrong with it that Im quickly learning!!!!

[Bill Badger]

I have today checked with my main dealer using the car registration details, and I am told that this model doesn't have the Dual Mass Flywheel.

I hope this information may be of help to someone else.

[Bill Badger]

I have now successfully replaced the clutch. Whilst pleased at the result, I must say that the right tools are essential - hoist, stands etc. Also essential is a beefy mate who can help with lifting the heavy box when ready to install.

Top tip came from my 85 year old retired mechanic father: Make up two or three studs from threaded bar or long bolts. These really help when putting the box back in because you can hook the box on to these and so reduce the chance of damaging or moving the (hopefully) aligned clutch plate.

The use of a Haynes book is very beneficial, although you do need to weed out the non essential instructions such as draining the gearbox oil. This does not need to be drained for changing the clutch.

Another thing to be careful of is the speedo drive. Just disconnecting the connector isn't enough, since trying to find somewhere to hold on to the box when removing ends up with grabbing the drive, with possible expensive results!

One last note - The Europarts web listing for the AGN engine is wrong, and it suggests that the car has a dual mass flywheel, which it does not! Following their link also sets you up to buy a 220mm clutch for the turbo model, even though the required clutch is a 215mm...... Be careful!