MKIV VR6 Transmission Removal / Clutch
Contents
1. Member a VOLES AGE ET Offline Member Since 3 24 2006 890 posts u should get an award for that like a little sir name on ur SN so that everyone knows that u know what the hell ur talking about ur a winner Bethesda MD 2003 Volkswagen Jetta 24v GLI ES a http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums bigmak Member Offline Member Since 1 5 2004 22089 posts Fairfax Blacksburg VA mhmm m a VgRt6 Moderator Offline Member Since 3 7 2002 10548 posts Germantown MD 99 5 Jetta GLS VR6 m a http forums vwvortex com zerothread 1id 2703042 DIY MKIV VR6 Transmission Removal Clutch Replacement Page 39 of 44 8 21 PM 7 9 2006 Cs a B Re shadowmilkman gt another great faelin diy guide Mikey aim bigmak040 my site 42 draft designs melissa theuriau 23 29 25 Bellaheather i m such a post whore 23 29 30 Bellaheather i cant stop ii eurogruppe holland michigan Club Whore Status w 5 Re DIY MKIV VR6 Transmission Removal Clutch Replacement FaelinGL 10 2006 Quote originally posted by FaelinGL BTW did you check your clutch disc very closely The disc on mine was in excellent condition however I noticed a hairline fracture running along the metal in the center We checked it very closely My clutch disc had very little visible wear even at 147k miles There were no cracks visi2. prepared for it to move once the bolts are removed Then remove the two 16 mm bolts holding the mount to the frame www fallastarmedia com 36 Support both the engine and the transmission with jacks Use a piece of wood to even out the load Make sure both jacks are supporting some of the weight This is also your opportunity to verify nothing else is connected to the transmission Tie up any cables wires or connectors so they are out of the way http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 22 of 44 par ii www fallastarmedia com Note This step will remove the transmission support from the frame Only the jack will be supporting the weight of the transmission 37 Unscrew the two 18 mm transmission mount bolts Make sure the jack is supporting the weight before you remove them fully http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 23 of 44 ad rpe z 2 i il wer F il www fallastarmedia com 38 Locate the three bolts on the driver s side of the transmission These three secure the transmission to an intermediate metal piece You will need to lower the engine transmission a bit to access these bolts Start by lowering the engine jack a bit then lower the transmission jack a bit and repeat until you can see the three bolts www fa
3. Replace the old throwout bearing on the fork with the new one This is very easy to do you will see how once you get the fork out Once replaced reinstall the fork You may find it easier to remove the retainer spring from the fork pivot install the spring into the fork and press the retainer onto the pivot 52 Check the operation of the new throwout bearing It should slide very easily on the input shaft 53 Remove the pressure plate and clutch disc by unscrewing the six 10 mm 12 point bolts Then use a medium screwdriver and slowly work the pressure plate out Be careful because once the pressure plate comes out the clutch disc will fall out as well 54 Perform this step ONLY if you need the flywheel removed ie for timing chain replacement or if installing an upgraded flywheel Remove the ten 10 mm triple square bolts holding the flywheel to the engine output flange An impact wrench is really useful here If you are using a breaker bar you will need someone to hold the crank pulley with a 27 mm socket to prevent the engine from rotating At this point the transmission the pressure plate the clutch disc and the flywheel are all removed The following steps are for reinstallation of the above components Tired of getting ripped off at the STEALERSHIP http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 30 of 44 FaelinGL Member Offli
4. found the proper orientation of the pressure plate press it onto the dowels Gently tap around the edges on the pressure plate with a rubber mallet to press the plate flush against the engine When installing the screws it is important at first to tighten the six screws only finger tight 58 Once the pressure plate screws are installed finger tight re align the clutch disc Use the socket to press the clutch disc in the appropriate direction until the hole in the clutch disc is perfectly aligned with the hole in the flywheel Once you are satisfied with the centering torque the pressure plate bolts in a diagonal pattern to 10 ft lbs 58 Reinstall the transmission Again easier said then done You will need to lift the transmission up into the engine bay and align the input shaft so it slides into the clutch and the dowels on the engine line up with those on the transmission Don t forget to bring the black A C line underneath the transmission 59 Once the transmission is flush with the engine reinstall the bolts you removed holding the engine transmission together Hopefully you labeled them so that you know exactly which bolt goes where Torque the 16 mm bolts to 30 ft lbs and the 18 mm bolts to 60 ft lbs 60 Reinstall the ground strap to the top combo bolt and tighten the 13 mm nut to 15 ft lbs 61 Reinstall the intermediate metal piece to the side of the transmission Torque the 16 mm bolts to 37 ft lbs 62 Jack up the engine tra
5. it transfers its energy into the fluid which also rotates The force travels through the fluid and eventually rotates the second impeller This motion allows the engine to rotate at a different speed while the transmission and wheels catch up The second is the use of friction In a manual transmission the rotation from the engine ends with the flywheel The flywheel provides a mating surface between one side of the clutch disc and on the other side the pressure plate So as the flywheel turns frictional force turns the clutch which is pressed against the flywheel by the pressure plate When you step on the clutch pedal you are seperating the pressure plate from the clutch disc Since the pressure plate is what keeps the clutch disc pressed against the flywheel seperating the two reduces the force transferred from the engine to the clutch To get the force to the transmission the center of the clutch has a splined shaft that the transmission input shaft goes in to A word of note from your friend and mine Gary VgRt6 When the tranny is out it s the perfect time to replace the thermostat on a VR6 That job is a real PITA when the tranny is in place This is exactly what I did and you can see why later on in the thread but it will add a couple of extra hours to your job Seriously worth it if you have not done it yet It will fail And I recommend draining the crack pipe before pulling anything off if you decide to do it by performing
6. similar Gary Now 99 5 Jetta GLS VR6 it 210 000 miles and counting and no CEL i Then 90 Passat GL 16v RIP i e Rest in Pain in a junkyard somewhere you LEMON POS still loved her though Free VAG COM scans in the DC area IM me The Official VgRt6 MKIV VR6 DIY Thread Master List 3 11 PM 7 27 2006 a E Re VgRt6 Amazing DIY write up a a a a dh a B T Stage I I Golf IV amp Jetta IV Quick Reply http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 44 of 44 K amp L Clutch amp Transmission Clutch Kit Info SpecRite Twin Disc Rockford PTO Clark Allison Get Info on Clutch Kit from 14 Search Engines Performanc E Distributor ini Torque Cor www kliclutch com www info com ClutchKit www specr For advertising information Click Here Powered by ZeroForum 2 1 2 2005 RelyNet Inc http forums vwvortex com zerothread 1id 2703042 9 8 2006
7. to raise the engine to a little below its normal ride height Work the black A C line until it is above the transmission and lower the transmission jack a bit Slide the transmission off a bit and lower the jack a bit more You will need to turn the transmission counterclockwise to get it around the subframe and then it will drop right down If you are http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 29 of 44 relatively strong you can bench the transmission it weighs about 80 pounds and work it out Use the jack as a resting point when you are tired This could take a while so if you need to take a break make sure the transmission is supported and rest for a bit www fallastarmedia com 49 Finally out While out take the opportunity to clean things up Remove the clutch fork by unclipping the metal retaining clip at the bottom Press the metal fingers up and out of the hole in the fork Then slide the fork off of the transmission input shaft along with the throwout bearing 50 Once the fork is out clean the input shaft Remove any dirt or corrosion products and apply a light coat of moly grease to the input shaft You want to grease both the splined part AND the smooth part of the shaft This allows the throwout bearing to glide easily on the shaft Also apply a thin film of moly grease to the fork pivot at the bottom of the transmission 51
8. way Also see the white guide rail on the left side This provides rotational guidance for the shift weight http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 10 of 44 Talwe ity iteh bl Di 14 Once the spray has settled for a few minutes wiggle the shifter weight back and forth to slide it off the spline This is a shot with the weight removed and the white plastic guide rail exposed ate RSS ALT ie dial ma a Ti a www fallastarmedia com 15 Remove the connector for the reverse light indication The connector is rather difficult to get to but it will come out http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 11 of 44 if EES www fallastarmedia com 17 Remove the three 13 mm bolts holding the black metal bracket in place It is still attached to the transmission selector cables leave them attached http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 12 of 44 18 Slide the gate selector cable out of the transmission connection Note the plastic sleeves on either side of the shaft Remove these as well www fallastarmedia com 19 Located towards the rear of the transmission find the heat shielding bag that encl
9. 02 20805 posts MIAMI its euro thats all you have to know VERY EURO ES a wzcunningham Member Offline Member Since 3 29 2006 1409 posts Mount Laurel NJ 2003 GTI 1 8T 5spd all OEMness m ap UntouchableGTI Member VOLES GER Aaa Offline Member Since 4 30 2006 1366 posts Waukesha WI 02 GTI 1 8T m aD Gary Now 99 5 Jetta GLS VR6 it 210 000 miles and counting and no CEL i Then 90 Passat GL 16v a RIP i e Rest in Pain in a junkyard somewhere you LEMON POS still loved her though Free VAG COM scans in the DC area IM me The Official VgRt6 MKIV VR6 DIY Thread Master List E Re VgRt6 6 14 AM 7 11 2006 WOW now thats a DIY ga English I would like to buy a hamburger Euro A wiad like toa bye a damburgaaaar MY prriu E Buy my Oettinger grill E Re Pifiu gt 6 19 AM 7 11 2006 thank you Quote originally posted by stormdc God damn bible thumpers WHy would a god troll troll a car forum hahahaha E Re DIY MKIV VR6 Transmission Removal Clutch lt lt 10 22 PM 2 7 Replacement Elvir 2006 awsome great job man now go do the 1 8T Elvir I will have my write up DIY on a 1 8T clutch transmission removal by like sunday so keep ur eyes out for it i know the vr6 is similar but im sure the 1 8t has a few diff quarks so cant hurt and i will be using this diy as a type of guide Bump for a grea
10. Do you have any more pics of the removal of the drive flange from the tranny That almost warrants its own DIY translate I want more pics because I ll have to do it eventually Gary Now 99 5 Jetta GLS VR6 it 210 000 miles and counting and no CEL i Then 90 Passat GL 16v RIP i e Rest in Pain in a junkyard somewhere you LEMON POS still loved her though Free VAG COM scans in the DC area IM me The Official VgRt6 MKIV VR6 DIY Thread Master List 5 Re DIY MKIV VR6 Transmission Removal Clutch Replacement VgRt6 lt gt A30 PM na Reply 2006 Meply Quote originally posted by VgRt6 Awesome job E The two of us should go into business together a T I m adding a link to this in my timing chain DIY Now I don t have to put my own tranny DIY together Thanks for saving me a ton of work and likely my marriage too Do you have any more pics of the removal of the drive flange from the tranny That almost warrants its own DIY translate I want more pics because I ll have to do it eventually m Larry thanks for the additions it has been done No worries Gary I got to keep you going to 300k BTW did you check your clutch disc very closely The disc on mine was in excellent condition however I noticed a hairline fracture running along the metal in the center 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 38 of 44 As far as the driv
11. Member Offline Member Since 12 27 2005 806 posts Rapids Wi VW jetta 1 8t m ap mattyrj Member McLaren Offline Member Since 11 21 2005 952 posts A High School in Fl A Diesel one ES a OhioVr6 Member Offline Member Since 8 5 2002 4283 posts Oxford Ohio m ap Elvir Member DIY MKIV VR6 Transmission Removal Clutch Replacement damn thanks for the write up im gonna be doin that soon Re cdkirgis gt gt E vortex DIY ers nevar seize to amaze me B Re jakanapapa dayum Mad props to you son ia Km Quote originally posted by Rob sVR6 1 you so much it hurts ouch TDI nevar looZeS Depressed Sad Emo Then go here a m E Re mattyrj gt This is the reason I love vortex props an go Nothing in the world can take the place of persistence Dub Society Re DIY MKIV VR6 Transmission Removal Clutch Replacement FaelinGL gt http forums vwvortex com zerothread 1id 2703042 2 51 AM 7 9 2006 6 47 AM 7 9 2006 6 49 AM 7 9 2006 6 50 AM 7 9 2006 Page 33 of 44 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 34 of 44 J i ee Cove awsome great job man now go do the 1 8T Offline Member Since Elvir 10 18 2004 6297 posts Durty Durty GA Nopi Naitonals 06 September 16 17 wh I drive a Mini Cooper Inspired Vte
12. VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 1 of 44 RIMS s ZRON the volkswagen enthusiast website Ronal makes the OEM wheels f vortex forums features galleries resources marketplace Golf IV amp Jetta IV Forum oe is My Profile Active Users Help Search Google Search VWvortex Forums Golf IV amp Jetta IV DIY MKIV VR6 Fost New Topic New Topic Start New Poll Transmission Removal Clutch Replacement Archived a jt MA T DERSE E PARR D wasto EE FaelinGL DIY MKIV VR6 Transmission Removal Clutch 1 34 AM o Member Replacement 2006 Offline Member Since 11 27 2004 DIY MKIV 12v VR6 Tranny Removal Clutch Replacement 854 posts For Clutch replacement or for Lower Timing Chain replacement Charlotte NC The MKIV VR6 transmission removal is required to perform lower timing chain replacement as well 2000 Jetta VR6 as upgrading or replacing the clutch To fully understand how the clutch operates there are some aan aes excellent articles in the manual transmission forum but I will cover the basics before we begin counting m In order to take the rotation force provided by the engine and send it to the transmission we have two basic methods The first used in automatic transmissions is called a Torque Converter In the torque converter two impellers like propepeller blades are placed inside a chamber filled with fluid As one impeller rotates
13. ble I look for them for a living so I know what to look for my clutch disc at 147k miles Here s a pic of Quote originally posted by FaelinGL As far as the drive flange what you see above should do it After draining the tranny fluid unscrew the 5 mm conical bolt and slide the flange out Really really easy I would assume the driver s side is exactly the same Make sure you have someone stepping on the brakes or you are holding the flange so it doesn t turn when you 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 40 of 44 remove the conical bolt So it just slides out easily Perfect I heard it was easy but didn t realize it was that easy Having that flange out of the way will make removing and installing the tranny 10 times easier Gary Now 99 5 Jetta GLS VR6 it 210 000 miles and counting oy and no CEL i Then 90 Passat GL 16v RIP i e Rest in Pain in a junkyard somewhere you LEMON POS still loved her though Free VAG COM scans in the DC area IM me The Official VgRt6 MKIV VR6 DIY Thread Master List superherosean Re DIY MKIV VR6 Transmission Removal Clutch 4 56 AM an Member Replacement FaelinGL gt gt 10 2006 Offline os Member Since 2 26 2006 883 posts That s thirty minutes away I ll be there in ten pj ny WTB stock or stubby mirrors indi or black eo Ve http forums vwvortex com zerothread
14. ch badged W H20 International September 22 25 tO hampster powered VW shiftered one I cannot help but think a curious event is this life of mine S wheel drive Geo ES a 1 8TIM Re DIY MKIV VR6 Transmission Removal Clutch lt gt 7 11 AM Member Replacement Elvir gt gt 2006 Offline Member Since 3 28 2002 4360 posts QUEENS NY 2003 SS GRAY GTI 1 8T m a http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 35 of 44 looks like either racoon or cat meat all over there Seer Pee ee ee ee eee eee eee eee s Peer C amp M Performance Home of the World s Fastest FWD VW 9 536 148 6mph FaelinGL Re DIY MKIV VR6 Transmission Removal Clutch 10 20 AM a Member Replacement 1 8TIM 2006 Member Since 11 27 2004 Quote originally posted by 1 8TIM 854 posts looks like either racoon or cat meat all over there http forums vwvortex com zerothread id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 36 of 44 Charlotte NC 2000 Jetta VR6 Or a leaky T stat housing for 30k plus miles T 150k and counting Mike 5 am Tired of getting ripped off at the STEALERSHIP Step by step MKIV DIY Video DVD s are HERE 50 off for Vortex Members Email me at contact fallastarmedia com Blazing GTI E Re DIY MKIV VR6 Transmission Remova
15. e flange what you see above should do it After draining the tranny fluid unscrew the 5 mm conical bolt and slide the flange out Really really easy I would assume the driver s side is exactly the same Make sure you have someone stepping on the brakes or you are holding the flange so it doesn t turn when you remove the conical bolt Mike Tired of getting ripped off at the STEALERSHIP Step by step MKIV DIY Video DVD s are HERE 50 off for Vortex Members Email me at contact fallastarmedia com hawaiian5 0 Re DIY MKIV VR6 Transmission Removal Clutch lt 7 44 PM o Member Replacement FaelinGL gt gt 2006 coy go very nicely done you need to have a few of these for that write up D Geb Gat fat a Offline Member Since I hate the 1 8T engine i 11 29 2005 ASROR The Ohio State University Alum princeville hi 2 bad a ridesin Quote originally posted by Chacolla the 808 your driveway looks like it could be used as a half pipe for the x games A om JamieK18T E Re DIY MKIV VR6 Transmission Removal Clutch 8 13 PM Member Replacement Elvir gt 2006 Quote originally posted by Elvir awsome great job man now go do the 1 8T ffli idl Elvir Member Since 1 14 2002 4655 sn not much of difference Louisville KY 01 GTI 94 Jetta 87 Jetta Coupe 01 GTI 01 Jetta R I P 1991 Alfa Romeo 164S E a 1990 Civic B16A shadowmilkman gt 8 19 PM 7 9 2006
16. e transmission remove the two 18 mm and one 16 mm bolts If yours looks like this you may want to call MJM at this point and express mail a crack pipe and T stat housing kit http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 27 of 44 45 Remove the two 16 mm bolts towards the rear of the engine transmission near the passenger s side CV joint Note The output flange is not removed in this picture disregard this discrepancy http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 28 of 44 www fallastarmedia com 46 Remove the last 16 mm bolt on the bottom of the connecting the engine and the transmission I do not have a picture of this bolt but it is the farthest one down on the transmission 47 The transmission will not immediately seperate from the engine because the transmission input shaft is still inside the flywheel To seperate the two give the mating joint a couple of raps at each segment Then gently work the transmission off of the engine Remember the jack is your friend It will support the weight of the transmission for you but it cannot move the transmission Seperate the two just a little bit for now www fallastarmedia com 48 Remove the transmission from its place in the engine bay Easier said then done The best advice I can offer is
17. eat stuff Member Since 11 24 2001 18981 posts Larry Las Vegas Nevada ee On ae Proudly Brought to you by Wally The Wonder Llama http forums vwvortex com zerothread id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Futura Yellow and a very very mad Snail ES a VR6 Seige Member Offline Member Since 9 8 2004 1317 posts Exton Pottstown PA o1 gtI vR6 m a VgRt6 Moderator Offline Member Since 3 7 2002 10548 posts Germantown MD 99 5 Jetta GLS VR6 m ap FaelinGL Member Offline Member Since 11 27 2004 854 posts Charlotte NC 2000 Jetta VR6 150k and counting m ap http forums vwvortex com zerothread id 2703042 Page 37 of 44 if you are ballz deep then sadly you have a small weenie My Wife Forum Rules FAQ s and New User Guide Generic OBDII Codes 5 Re DIY MKIV VR6 Transmission Removal Clutch Replacement FaelinGL lt 11 47 AM a oo 2006 not looking forward to replacing my clutch but great DIY thanks an my car owns me wip Fr OEM Headlights 5 Re DIY MKIV VR6 Transmission Removal Clutch Replacement VR6 Seige 2006 Awesome job bd The two of us should go into business together dh I m adding a link to this in my timing chain DIY Now I don t have to put my own tranny DIY together Thanks for saving me a ton of work and likely my marriage too
18. econnect the MAF connector and reinstall the interior components by performing steps 7 f to 7 j of the Starter Motor Grind Fix Replacement DIY 89 Before you start the car and take it for a test drive go through all the gears to make sure that each engages properly Also make sure the clutch pedal feels proper Then start the car and take it for a very slow test drive You will need about 500 miles to break in the new clutch That s it Please let me know with any mistakes or corrections Congratulate yourself on completing a very intense DIY Mike Modified by FaelinGL at 7 27 PM 7 9 2006 Tired of getting ripped off at the STEALERSHIP Step by step MKIV DIY Video DVD s are HERE 50 off for Vortex Members Email me at contact fallastarmedia com bryan burnick Re DIY MKIV VR6 Transmission Removal Clutch 1 36 AM o Reply Member Replacement FaelinGL 2006 YOLE SAADEH Ciater ri Offline awesome DIY all i need now is the for a new clutch flywheel Member Since 9 16 2005 1879 posts http www youtube com watch v kVJj5CdC8Bk birmingham al PED NA putfile com bryanburnick 1999 5 jetta vr6 http www villagehobbycentre com jokes html m ap cdkirgis B 1 39 AM 7 9 2006 Member VOLES WAGE tach Offline http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums Member Since 7 8 2005 404 posts Anchorage AK 2004 VW GTI 1 8T ES a jakanapapa
19. id 2790154 amy infinityman Re DIY MKIV VR6 Transmission Removal Clutch 5 29 AM a Member Replacement superherosean 10 2006 VOLES WaGEH acing thumbs up to you mang a Offline will this DIY work the same for the 1 8t AWP Member Since 9 2 2004 2205 posts Polished Montes Shaved hatch R S S R tails APR 3 TB n75 H Koni Yellows GroundControl midland mi Coilover kit 350 325 eibach springs SPC camber plates 28mm neuspeed rsb BFI upper rear tie 2002 GTI bar 20th recaros 710N DV 10mm 20mm spacers K amp N filter Audi TT short shift Prothane 1 8turbo AWP dogbone painted valences Splitter Black grill 20th headlights Hankook RS2 s Stubby smoked corners repeaters shaved painted engine bay 5 Black0Ovr63 E Re DIY MKIV VR6 Transmission Removal Clutch 5 38 PM a Member Replacement FaelinGL gt 10 2006 OMG This is so sweet I have hoped a DIY would be done before I have to do mine Thank you so Offline much Member Since 6 7 2005 558 posts Representing Deutschland baltimore md 96 Jetta 2 Slow Sold 03 Gti 1 8T http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 41 of 44 Gone 2000 Jetta VR m ap Vdub12 B 5 46 PM 7 10 2006 MEME Member gt e ing sweet Offline Member Since 2 24 2003 PAGPARTS COM MEMORYFAB COM 11922 post pee Poe OPENROADTUNING COM Down Your Th
20. ill have yours since the battery will be disconnected for a while 1 Start by removing some interior components Perform steps 1 a through 2 e of the Starter Motor Grind Fix Replacement DIY 2 a Remove the air filter To do this unscrew the two phillips head screws at the top of the air box cover They will not come all the way out za 4 www fallastarmedia com b Lift up on the top of the air box cover and slide the air box off of the retaining clips http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 4 of 44 www fallastarmedia com 3 Disconnect the MAF air sensor Insert a screwdriver blade in to the small hole at the end of the connector pry up gently and slide the connector off http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 5 of 44 4 Using a pair of Vise grips open and lock open the clamp connecting the air header to the air box Leave the clamp opened for now www fallastarmedia com 5 Slide the air header off the air box cover by rocking the header back and forth and pulling it off the air box cover http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 6 of 44 6 Disconnect the plastic hose attached to the air box cover Sq
21. l Clutch 10 54 AM Member Replacement FaelinGL 2006 wow that s exactly what I needed to see Thanks for all the excellent pictures it s greatly appreciated Offline Now I just need to figure out if I can pull it off in a weekend Member Since 3 31 2006 Quote originally posted by FaelinGL 41 posts DIY MKIV 12v VR6 Tranny Removal Clutch Replacement Culver City CA 2001 GTI 1 8T i Drive the vehicle to a well lit spot and chock the rear tires You will be here for a couple of hours so make sure you can leave the car here undisturbed 5 im couple hours always turns into couple days plus 9 trips to pep boys for me i A good friend will bail you out of jail A best friend will be in jail with you saying That was AWSOME SPKNGRMN E Re DIY MKIV VR6 Transmission Removal Clutch 11 35 AM Member Replacement Blazing GTI 9 2006 l wow Mikel Ge I won t even ask how long it took you to write up this DIY thread Offline That s unreal how thorough it is Job well done a Member Since 7 24 2002 6421 posts Wes facia soloROGUEsty ez Shuffle Up amp Deal Trail Charlotte NC P 02 5 20VT tipMODic GUCCI sunroof motor covers gt http forums vwvortex com zerothread id 2763637 IM me for details 5 LSinLV Re DIY MKIV VR6 Transmission Removal Clutch 11 35 AM Reply Moderator Replacement SPKNGRMN 9 2006 Offline will be added to the DIY s gr
22. ll spend many hours trying to get the passenger s side transmission output flange past the flywheel but after removing the flange the transmission came right out However in order to remove the flange you must first drain the transmission 32 Place a drip pan underneath the transmission and remove the 17 mm allen bolt under the transmission This will drain all the transmission fluid Once drained reinstall the bolt until it is tight www fallastarmedia com 33 Locate the 5 mm conical bolt holding the passenger s side transmission output flange in place While holding the output flange or having someone step on the brakes remove the conical bolt The output flange has a spring on the inside and should pop right out Be gentle when removing the flange as it has two sealing surfaces to keep the transmission fluid in http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 20 of 44 lt a www fallastarmedia com a mhi 34 Repeat steps 30 and 31 for the driver s side CV joint http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 21 of 44 t y www fallastarmedia com 35 Remove the pendulum mount aka dog bone by unscrewing the two 18 mm bolts connecting the mount to the transmission The engine transmission may swing down about an inch so be
23. llastarmedia com 39 Here the engine transmission is lowered enough to access the three bolts Remove them with a 16 mm socket http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 24 of 44 www fallastarmedia com 40 Once the three bolts are removed remove the intermediate metal piece by pulling it up and away You may need to lower the engine transmission a touch more to get it out www fallastarmedia com 41 Now you are ready to start seperating the engine from the transmission Start with the combo bolt near the top of the transmission Remove the 13 mm nut connecting the ground strap to the combo bolt and slide off the ground strap Then remove the 18 mm combo bolt http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 25 of 44 42 Remove the other 18 mm combo bolt towards the front of the transmission still on the top I swear it is underneath this mess of rubber and pipe to the right of the starter motor socket Oer combo bee ee www fallastarmedia com 43 This is a better view of the second 18 mm combo bolt http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 26 of 44 www fallastarmedia com 44 Looking at the front of the engin
24. mission Removal Clutch Replacement Page 31 of 44 PE www fallastarmedia com 68 Reinstall the white plastic heat shield and tighten the two 13 mm bolts to 26 ft lbs 69 Gently reinstall the slave cylinder into the transmission You will have to press it in but make sure that the shaft is straight when you tighten the bolts Torque the 13 mm bolts to 18 ft lbs 70 Reinstall the black support member and tighten the 16 mm bolts to 18 ft lbs 71 Reinstall the starter motor by performing steps 7 a through 7 e of the Starter Motor Grind Fix Replacement DIY 72 Reinstall the plastic piece into the driver s side fender well and secure it with the 10 Torx 25 SCrews 73 Reinstall the driver s side splash guard by tightening the star washers with the long blade screwdriver 74 Reinstall the center splash guard by tightening the four Torx 25 screws 75 Reinstall the front wheels and torque them to 90 ft lbs Once the wheels are installed lower the front of the vehicle 76 Reinstall the connector for the VSS This is the one on the rear of the transmission with the heat shielded bag 77 Install the heat shielded bag by sliding the bag on top of the sensor and snapping the snaps into place 78 Lightly lubricate the inside of the white plastic sleeves from the gate selector cable shaft with a Q tip Then slide the plastic sleeves into their appropriate spots in the shaft and slide the gate selector cable shaft into i
25. ne Member Since 11 27 2004 854 posts Charlotte NC 2000 Jetta VR6 150k and counting m a Step by step MKIV DIY Video DVD s are HERE 50 off for Vortex Members Email me at contact fallastarmedia com Re DIY MKIV VR6 Transmission Removal Clutch 1 35 AM 7 9 Reply Replacement FaelinGL 2006 55 Reinstall the flywheel by aligning it to the engine output flange There is one bolt hole that is offset a little bit from the rest to guarantee the flywheel is installed properly Once you have aligned this one bolt hole install all 10 bolts finger tight Using a diagonal tightening pattern tighten the flywheel bolts to 44 ft lbs plus 1 4 of a turn You will need someone else to hold the crank pulley with a 27 mm socket while you are tightening the bolts 56 Reinstall the clutch disc You will need to center it on the flywheel so that the transmission input shaft slides onto the clutch disc properly The easiest way to do this is to find a socket metric or standard that fits into the center of the disc and into the center of the flywheel Then place the clutch disc onto the face of the flywheel with the socket pressed into the flywheel The clutch disc will sag until the pressure plate is installed so don t worry right now if the alignment is not perfect 57 Reinstall the pressure plate The pressure plate will align only one way with the dowels on the engine and allow you to install all six bolts When you have
26. nsmission until you can install the two 18 mm transmission mount bolts With the mount faces flush ie no preload torque the 18 mm bolts to 74 ft lbs 63 Remove the wire holding the driver s side CV joint in place and slide the CV into the transmission output flange Reinstall the 6 triple square bolts into the flange tightening diagonally to 52 ft lbs I found it very useful to have a friend press the brakes when I applied the torque and released when I needed to move to another bolt I also numbered each bolt on the flange itself so I knew in what order to tighten each 64 With the brake applied slide the passenger s side output flange into the socket Reinstall the 5 mm conical bolt while pressing in on the flange You will need to compress the spring quite a bit in order to get the bolt to catch Torque the conical bolt to 18 ft lbs 65 Repeat step 63 for the passenger s side CV joint and output flange 66 Reinstall the dog bone mount The 18 mm bolts are torqued to 30 ft lbs and the 16 mm bolts are torqued to 15 ft lbs add an extra 1 4 of a turn if you are installing new bolts for both the 18 mm and 16 mm bolts 67 Refill the transmission by removing the 17 mm bolt at the front of the transmission and adding gear oil until it begins to drip out of the bottom of the hole Then reinstall the 17 mm bolt and turn clockwise until tight http forums vwvortex com zerothread id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Trans
27. oses the vehicle speed sensor VSS Unsnap the two snaps that close the bag and slide it up the cable http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 13 of 44 www fallastarmedia com 20 Remove the connector from the VSS Again this may be difficult to get to www fallastarmedia com 21 Now you are ready to get underneath the vehicle Raise the front end of the vehicle and remove the front wheels 22 Remove the center splash guard by performing step 3 of the VR6 12V Oil Change DIY 23 Remove the driver s side splash guard by inserting a long blade screwdriver into one of the slots on on the star shaped washer Then unscrew the washer and it will work the guard off of the stud in the frame There are two of these washers for the guard Once removed the guard will drop right out http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 14 of 44 A www fallastarmedia com www fallastarmedia com 24 Remove the driver s side fender well piece by unscrewing the 10 or so Torx 25 screws at the front and the back of the well Once removed the plastic piece should fall right out http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 15 of 44 y w
28. point bit is commonly called a Triple Square bit and is found in your local auto parts store Remove the six 10 mm twelve point bolts and the passenger s CV joint should separate from the transmission If you have an extra person it helps if they step on the brakes while removing the bolts I had a lot of trouble removing these bolts until I got an impact wrench Then they came right out http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 18 of 44 i j www fallastarmedia com Modified by FaelinGL at 4 36 AM 7 9 2006 Modified by FaelinGL at 7 23 PM 7 9 2006 Modified by FaelinGL at 1 43 AM 7 13 2006 Modified by FaelinGL at 11 52 PM 7 19 2006 Tired of getting ripped off at the STEALERSHIP Step by step MKIV DIY Video DVD s are HERE 50 off for Vortex Members Email me at contact fallastarmedia com FaelinGL Re DIY MKIV VR6 Transmission Removal Clutch 1 35 AM a Member Replacement FaelinGL gt gt 2006 Offline Member Since 11 27 2004 854 posts Charlotte NC 2000 Jetta VR6 150k and counting m a 31 Secure the passenger s side CV joint out of the way with some wire http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 19 of 44 Note Steps 32 through 34 are OPTIONAL but again HIGHLY recommended You wi
29. roat azy AZN E Re Vdub12 6 01 PM 7 10 2006 ML a Member a This should be added to the DIY section of the MK4 FAQs and with his other DIY too Great job ine Member Since 7 13 2003 a 628 posts 1992 8v GTI Project in progress The project died Car was sold August 2005 Kensington MD 2001 GTI VR6 1990 8v GTI Project in progress The project died Car was sold 1992 GTI July 2006 SV tSOLD 1990 GTI 8v SOLD 2001 VR6 GTI Project in progress A om ihe naan E Re LazyAzn 6 18 PM 7 10 2006 iL A Member on Mike IS the man a Had him over to the house today He VAGed scanned cleared coilpacked and multiple others things while he was here fflin He s local and you guys can t have him m Member Since 7 24 2002 6421 posts Wes Indian soloROGUEstylez Trail Charlotte NC Shuffle Up amp Deal 02 5 20VT UPHOBIE GUCCI sunroof a covers gt http forums vwvortex com zerothread id 2763637 IM me for details 5 am ho Re SPKNGRMN 4 29 AM 7 11 2006 Moderator This thread was added to the MKIV DIY thread in the transmission section http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 42 of 44 Offline Member Since 3 7 2002 10548 posts Germantown MD 99 5 Jetta GLS VR6 ES a Pifiu Member Fa Offline Member Since 1 27 20
30. similar manual transmission fluid or reuse the old fluid 10 new 10 mm triple square flywheel bolts if removing replacing the flywheel 6 new 10 mm 12 point pressure plate bolts New bolts for the pendulum dog bone mount if you are replacing them recommended Tools Required 27 mm socket 10 mm socket 13 mm socket 16 mm socket 18 mm socket 10 mm 12 point socket 17 mm allen wrench optional but recommended 10 mm Triple Square 12 point bit 12 ratchet extension ratchet Magic Marker Small blade screwdriver Large Vise grips Spray penetrating lubricant Medium phillips head screwdriver Impact wrench optional but HIGHLY recommended Rubber mallet Two jackstands Two jacks Small blocks of wood http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 3 of 44 Note I cannot be held responsible if something goes wrong during the performance of this procedure I have done my best to make it as accurate as possible but there may be some mistakes Please use your head when working with the jacks and the engine transmission combo Before you begin i Drive the vehicle to a well lit spot and chock the rear tires You will be here for a couple of hours SO make sure you can leave the car here undisturbed ii Once the vehicle is parked raise the hood iii You may need the radio code for OEM radio if you st
31. step 15 of the T stat replacement DIY as follows 15 Drain the crack pipe This one is messy The drain has to be accessed from underneath the car and is just next to the block where the water pump housing fits The stock pipe will need a flathead screwdriver and a turn or two then it pops off WEAR EYE PROTECTION Here s the plug you can only see it from underneath the vehicle If you just crack it about a half turn open a nice steady stream of coolant will come out into your awaiting bucket Wait 1 2 hour while draining and take a break MUCH MUCH better then spilling G12 all over your garage floor http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 2 of 44 Some very important cautions PLEASE label all the connectors parts and bolts you remove from the vehicle This will really help when you are ready to put it all back together Also some bolts are different lengths but look exactly the same as other bolts Use whatever labeling scheme works for you I used about 50 zip loc bags and a magic marker and some paper Parts Required Moly grease lubricant available at your local auto parts store also called Spline Lube New Clutch pressure plate throwout bearing if you are doing this procedure I recommend replacing regardless of mileage New Flywheel optional Lots of Zip loc bags or similar for labeling 2 Liters of MT 90 or
32. t write up a Modified by UntouchableGTI at 10 24 PM 7 25 2006 http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement DeltaP42 Member ASTON MARTIN Offline Member Since 2 7 2006 384 posts Fond Du Lac WI 1998 GTi Vr6 m ap VgRt6 Moderator Offline Member Since 3 7 2002 10548 posts Germantown MD 99 5 Jetta GLS VR6 ES a 2002GTI Member Offline Member Since 9 18 2001 4566 posts TX m ap Return to Golf IV amp Jetta IV Page 43 of 44 Pagparts com I have a crotch rocket aD ic it THANX BUT I HAVE A MKIV VR6 12V 2 8 ITS A RARE BUT ITS FAST LIKE HELL SMOKED A MAZDA 6 CRX INTEGRA ACCORD COROLLA SR AND I ONLY HAVE A COLD AIR INTAKE ivansalazar882006 1 02 PM 7 27 2006 B aside from engine bay removal stuff would this work for a mk3 Quote originally posted by Teufelhunde douchebagachu Proud contributor to the I just sold my 4000 98 Jetta for 12 grand thread of 2006 98 GTi VR6 Ghosts of the past 98 Neon R T 94 Spirit 3 0v6 89 Lebaron 2 4 turbo w stage2 amp FMIC 89 Nissan Pulsar NX Looking For mk1 2 lt 1000 in MI WI IL 1 31 PM 7 27 2006 Re DeltaP42 gt Quote originally posted by DeltaP42 aside from engine bay removal stuff would this work for a mk3 Other than the different engine trany mounts it should be very
33. ts place in the transmission 79 Reinstall the black metal bracket to the back of the transmission and tighten the three 13 mm bolts to 18 ft lbs 80 Slide the power steering hose back into its clip on the black metal bracket 81 Reinstall the connector for the reverse light indication towards the shifter weight spline http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 32 of 44 82 Slide the shifter weight into the spline aligning the thicker spline with the slot in the shifter weight Install the 13 mm nut and torque it to 18 ft lbs 83 Reinstall the circlip on the gate selector cable shaft by sliding it on ensuring it locks into place 84 Slide the air box into the engine bay with the air intake and rubber damper sliding into the right side of the air box Install the rear 13 mm bolt and tighten it until tight 85 Reconnect the smaller black plastic hose into the airbox cover by sliding it onto the cover until the snaps lock it into place 86 Open and lock open the clamp on the air box cover with a pair of vise grips and slide the air header pipe onto the air box cover When the header is fully installed onto the cover release the clamp 87 Install the air filter into the air box and slide the rear hooks of the air box cover into the air box Then tighten down the air box cover with the phillips head screwdriver until tight 88 R
34. ueeze the ribbed sides firmly and pull the hose off LO may E www fallastarmedia com 7 Release the clamp around the outlet of the air box cover by releasing the Vise grips At this point you should be able to remove the air box cover http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 7 of 44 www fallastarmedia com 9 Slide the air box out of the engine bay by pulling it to the passenger s side and lifting it up and out http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 8 of 44 10 Remove the circlip holding the gate selector cable in place by lifting up on the raised tab with a small blade screwdriver and sliding the clip off i 7 i hy i k E i i k My hi i ia hy i w Ty i i www fallastarmedia com 11 Locate the shifter weight retaining nut http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 9 of 44 12 While holding the shifter weight remove the retaining bolt with a 13 mm socket and extension i www fallastarmedia com 13 Spray a little penetrating lubricant into the spline area of the shifter weight While it is settling note that there is one thicker spline then the others This ensures the shifter weight goes in only one
35. ww fallastarmedia com 25 Remove the starter motor by performing steps 3 a to 5 b of the Starter Motor Grind Fix Replacement DIY 26 Remove the two 16 mm bolts holding the black support member in place The bolt on the left actually has a nut so do not forget to remove and bag it as well http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 16 of 44 yi www fallastarmedia com 27 Remove the two bolts holding the slave cylinder in place with a 13 mm socket gt NNN FT www fallastarmedia com 28 Carefully slide the slave cylinder out of the transmission Do NOT depress the clutch pedal while the slave cylinder is removed or you risk rupturing the rubber boot The base of the slave cylinder is plastic so be gentle as you remove it http forums vwvortex com zerothread 1id 2703042 9 8 2006 VWvortex Forums DIY MKIV VR6 Transmission Removal Clutch Replacement Page 17 of 44 i E I j E n F j i a ve P he Te Fa d ps E ki a pU ro a Ce H 3 Pa r i i y x oo ba ee oo Sa www fallastarmedia com 29 Locate the white plastic heat shield protecting the passenger s side CV joing Remove the two bolts holding the plastic shield in place with a 13 mm socket www fallastarmedia com 30 You can see the passenger s side CV joint here It is held to the transmission output flange by 6 twelve point bolts This 12
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