B5 Clutch Replacement

[steelroe]

I am about to replace the Clutch and pinion bearings on a 2004 1.9tdi passat. Is there a gearbox removal procedure available anywhere online.

[henry raison]

I am about to do the same job...local library has not got workshop manual so wonder how you did it in the end ..like you at present I cannot find any online assistance with the process but seems fairly straightforward if time allowed by VAG garages is just 4 hrs !!. I might do it in 4 days !!!

Any tips appreciated

[yaman]

http://www.audiworld.com/tech/eng48.shtml

Knock yourself out

The general principle the same

Regards
Jim

[henry raison]

Did the clutch job and although the workshop allow 4 hours these would be for about 3 mechanics I reckon !

Allow 10 hrs; to take apart with sized bolts etc and about 7 hrs and 10 cups of coffee to assemble..The hardest part was getting gearbox back to engine housing even with a Draper gearbox jack cradle from e bay . ( £49 well spent and essential ).

Took two of us to resolve refitting with one person pushing gearbox lying on back with both feet on gearbox housing and one person up front with jack /cradle and using eye up to align...the prob is you are working against gravity to replace if you use the axle stands nose up position as I did..

PS help to bleed clutch afterwards I found

Good luck and think of the £500 plus plus you can save....

[muddy]

Out of interest did you find much rust and dirt in the bellhousing?

When I changed the engine and clutch on my 1.8T I was amazed at how many 'spare' holes there were in the bellhousing and just how much rusting was underway on the clutch components and the grittyness on the release bearing sleeve.

Blocked off all but one and put a proper breather pipe in that location.

[henry raison]

No spare holes but mine was the first time clutch replacement..I understand "el cheapo" garages may not bother to replace some of the bell housing bolts since they are awkward to get to...especially the one on top of the bell housing...Not any rust in the bell housing but lots of dust from worn clutch and bearing warn but not gritty...perhaps your car has been in flood/ deep water conditions at some stage??.

Surprised how light the new clutch pedal is !! I thought clutch wasn,t working at first cos of fitting faulty pressure plate but not so fortunately.

Regards

henry