4Rings::G2 boosted::

With a lift and two of us working and only minimum breaks for food and drink it took us from 8am until 11pm to swap the clutch. That's right, full 15 hours of work. :blink:

Ended up having to remove the exhaust completely which necessitated removing the rear valance and all 5 (wideband also) O2 sensors. One of the rear O2 sensors got stripped so we had to disconnect it in the engine bay and leave in on the exhast.

The subframe had to be disconnected in the back and lowered, then all 3 driveshafts and tranny mounts, shields, tranny linkage and all the connectors. At least so we thought. Then we could remove the bell housing bolts and finally we were able to support the tranny on an oil tank cart on the lift and raise up the car further and slide it the tranny back and out of the way. The actual flywheel and clutch replacement was the easy part. Aligning the tranny and sliding it back in place took a bit of finesse. Then everything went back on in reverse order. At some point during reassembly I realized that we broke the cable on the rpm sensor that attaches to the bellhousing. Also, we tried bleeding the clutch but not sure if we were successful.
In the end the car is reassembed but not running due to the dead rpm sensor. So for now I'm leaving it on the lift. I should be able to replace the sensor and bleed the clutch next weekend and be good to go.
Here's some pics for ya.

<img src="http://tomasz.data2net.org/gallery-albums/album97/Passat_003_Large.jpg">

busted rpm sensor:

<img src="http://tomasz.data2net.org/gallery-albums/album97/Passat_010_Large.jpg">
<img src="http://tomasz.data2net.org/gallery-albums/album97/Passat_011_Large.jpg">

Half way there:

<img src="http://tomasz.data2net.org/gallery-albums/album97/Passat_012_Large.jpg">
<img src="http://tomasz.data2net.org/gallery-albums/album97/Passat_013_Large.jpg">
<img src="http://tomasz.data2net.org/gallery-albums/album97/Passat_014_Large.jpg">

4Rings::G2 boosted::

I owe you big time!

Blue TooTh Fan

Tom, I must say, you are the man!

Mat Indukts Lambos

Those mounts on the side of the trans, that are held on by 8mm allen bolts.......It takes 5-10 minutes to remove them, and makes it 1,000x easier to move the trans in &amp; out. 15 hours!? Gasp!!!

Oh, and you're not the first one to break an RPM sensor. ;-)

4Rings::G2 boosted::

it made it easier to align the clutch on reinstall as it would slide back and forth on the mounts. Maybe the other way it would've been easier, not sure.

4Rings::G2 boosted::

Does it have it's own plug or am I gonna have to rewire a common plug?

Mat Indukts Lambos

Just find the wiring that got ripped out, follow it up, you'll see.

Mat Indukts Lambos

I always hated those. On an occasional trans overhaul, I'd encounter a completely toasted trans. I cut the input shaft off a few of them, which makes the perfect alignment tool. ;-)

nunya

We dont all have shops, mostly shadetree. If you want to give out free input shafts i'll take one..

--dillon

4Rings::G2 boosted::

the plastic one worked fine. Thanks nunya.