FANTASTIC! Doing my Jetta now and this is my main reference. When you see the layout in 3D, you gain a better understanding of how your car is put together. Priceless info for me, thanks so much!
You've taught me more than school did already lol , Maybe not quite that much but for sure more about breaking down VW's and Audi's and since I work at an import shop it's very useful information. You have excellent instructional videos with 0 distractions and I appreciate that you make them Thank you.
Thank you very much... nice to hear! I appreciate you watching! Send me your mailing address and I'll send you some of my channel stickers... if you want some.
This video (along with part 2) is amazing! Took me right through a clutch swap in my 06 TDI. Really appreciate the time and effort that goes into sharing a pro's view with the rest of us!
Im a 4 year retired vw audi shop owner. And for some reason these keep popping up this week... Ive done sooooooo many damn clutches. They are a cake walk .
Nice job , have to save pat 2 for tonight and popcorn. Love the little guy with the tap,tap,tap and jeopardy ha. I would mind a nice polka once in a while :)
Well whaddaya know! This expert guy again paving the way for us curious diyer's and the dabbler's of the innards of our very own VW golf TDI's!! Thanks I'll be saving the two videos in this particular series to watch later, I'm hearing a slight rattle which o know to be the dmf, it's started recently after letting a local garage change the clutch.. tbf that was around 18 months ago, However I am leaning toward replacing with a single mass type just to eradicate the obvious flaw the 'improved' dmf is allegedly meant to be. Cheers mate.
Yeah, the flat rate Snapon rebuild service; can be a good deal. I have the 1/2" version IM51A; my first impact. Now, I have a older plastic body Ingersoll Rand IR-2131; much lighter and more powerful. I was skeptical of the plastic body but now appreciate, the less weight and power. I'm learning to appreciate; IR impacts. I think my favorite Snapon air tools are my FAR7200 3/8" ratchet (a beast) and my 1/4" FAR25A (fast)! Now my cordless little 7.2V screw driver; is a great way, to speed up the little stuff and fasteners. I highly recommend; all three! :)
Thanks for posting this video, you are doing an awesome work and i like it a lot. I am removing an engine from a passat 09 these days, this engine are going to be charged with a new one, and the gear box is an automatic. Do you have some advice for me, i have never done this kind of work. What is the important thing to think about? Thanks a lot.
If you don't already have a service manual... download it from here: erwin.vw.com/erwin/showHome.do Create a free user account and then pay for a 24hr subscription ($35USD). You can then download as much as you want and the pdf files will not expire (best deal online)! You need to be sure that you can raise & support the vehicle safely and that you can lower the engine & transmission safely... either together or individually. The torque converter bolt need to be removed so that the transmission can be pulled away from the engine. If it is a DSG transmission, then there are no torque converter bolts (easier transmission to remove). There's too much to list / suggest. If / when you have specific questions / issues... send me an email (you can also send pictures that way). Click on the fkh161 link in the description and then click on "tool request" to send questions.
Awesome video. You finally got a headlamp! You should check out the Zebralight H602w. MUCH brighter, and a very even distribution of light. perfect for working on cars. Oh, and much longer battery life.
Hey, I replaced the clutch in my son's 2008 jetta the same way you did,but it will not crank the battery and starter good I replaced the clutch potion sensor and nothing please help me great video thanks.
Replacing a clutch is mainly mechanical parts, aside from the battery & starter cables. The clutch pedal switch is the only other thing that could be the issue... but why now all of a sudden? It only makes sense that it is related to the starter or battery cables. Manually activate the starter with jumper cables... attach power & ground directly to the starter & battery via jumper cables. Then, trigger the starter by applying power to the starter solenoid (remove the trigger connector to expose the terminal). Starter should turn every time the solenoid is energized. If yes, not a starter problem.
Hi there, I´m about to change my DMF and Clutch on my Golf 5 1.9 TDI, I was wondering if I do need to unmount the Axle nut and exhaust system, would this guide work with my Golf ? Thx
So that it does not interfere / get caught on anything when removing the transmission. You can leave it in place if you like... you can do a lot of things different than what I did. There is always more than one way to remove something.
Yes, standard transmission mounting will be similar on the 2.5L... I'd have to check a manual to be sure (have not yet done one on a 2.5l) but I'm quite sure it will be similar.
Hi there, I have a vw golf mk5 1.9tdi 2007 and I was changing clutch kit but when I was tightening flywheel nuts it’s rotate a little bit so do I have to rotate it back before put gearbox back up or it doesn’t need to ? Thanks
Yes, only because the customer requested it. The transmission now rattles when it is in neutral and the clutch is not depressed. This is a side effect when switching to single mass. The dual mass absorbs the shocks of multiple injector firings (per cylinder)... that's why we usually only install dual mass.
On older TDI's it is not an issue as much, since the injector only fires 1 time. On the common rail engines, you have multiple injector firings per cylinder, per ignition / power stroke. That puts a lot of vibration into the crankshaft, which gets transmitted into the transmission, when a single mass is used. I was surprised that this BRM engine had a rattle afterwards. Yes, some DMF's fail early, but it's the best design to use on these engines.
Asbestos hasn't been used for quite some time... doesn't matter what the old one was, if you order the correct part for what the vehicle requires, you just install that.
@Razvan Negoitescu I would change it every 60k to 80K km's (37k to 50k miles). Some people change it sooner, some later. Personal preference. I think the dealer maintenance chart says to check every 20K miles and top up if needed.
Short answer: yes Long answer: Your 6 speed will look different compared to the 5 speed and will have slight mounting differences as well as linkage differences. Here's a 6 speed removal video on an A6/mk6 GTI (which should be similar to your vehicle). th-cam.com/video/ZGj30dpoNfk/w-d-xo.html
Im considering replacing the transmission in my 2006 jetta 2.5l manual 5 speed due to intermittent grinding when going into 5th gear and the transmission shop believes its due to a synchro. Would this video be similar to doing that task? Also any recommendations on buying a tranny online or should i consider getting synchro replaced? Thank you for making the video
This will be similar to your vehicle... I have a tendency to remove more than need be. 5th gear / syncro can be accessed with the transmission in the vehicle (if I recall correctly) Just the end cover needs to be removed. I'm currently at work... can look for & send you information once I am at home later tonight.
In North America it's a BRM engine... I'm not sure what the exact differences are. I'd have to find service info (since we don't have Touran in North America). It's a PD TDI engine... the BRM).
Should be similar procedure. I can send you some service info for transmission removal and turbo removal. Send me an email and I'll reply once I have found the service info: fkh161 @ fkh161 .ca (no spaces)
+Paul Bilek 9mm twelve point socket or 6mm triple square bit for the pressure plate bolts (depending on which bolts it has). I'll post a picture later.
+Supreme Lurker Yes...this one is blue-point (cheap snap-on). It makes more noise than it actually is good for. Electric ratchets might actually be more convenient than air ratchet. I'm saving up for electric impact gun & ratchet.
I can't help if you don't reply. The title of the video says clutch replacement (as in manual transmission)... watching the video would reveal / show shifter cable removal (standard transmission components).
None would hire me (fresh out of high school with no experience). I worked for a GM dealership for 6 months as a parts driver... hoping to get into the service department. Had enough after 6 months and started knocking on doors again. Found a couple of Germans running a small VW shop... and the rest is history. :-)
+StopDropandLOL There're times when I think that I should have moved on (worked at several different places to gain different experiences)... but I don't think I would have been able to accumulate the tools as I have been. I've seen a lot of guys come & go... guess I'm old school, I stick with the place that gave me a shot. :-)
Hello Thomas, I have got a car exactly like this engine code CFFB and the primary fuel pump that's before the fuel filter in the engine bay is making a serious buzzing , is this normal? It should be like this or the pump is on the go and I will need a new one?th-cam.com/video/O3ORLjrQKw8/w-d-xo.html
@@EXOVCDS the car is 2010 so this is 9.5 years old, I did change the fuel filter just before the buzzing, so before I take the old filter out I soak the new filter in diesel attached and also filled the filter bottle to the top, and the car started with first turn, I didn't use anything to prime the pump, it might be the small air, but the car would not start with first key. Did you ever meet a situation like this?
No... I always prime the system by running the fuel pumps (before I start the engine). I do this for 2 to 4 minutes before I start the engine. Air in the high pressure pump can cause damage... that's why I always prime with the pumps.
FANTASTIC! Doing my Jetta now and this is my main reference. When you see the layout in 3D, you gain a better understanding of how your car is put together. Priceless info for me, thanks so much!
Thank you for watching... let me know if you run into any issues.
You've taught me more than school did already lol , Maybe not quite that much but for sure more about breaking down VW's and Audi's and since I work at an import shop it's very useful information. You have excellent instructional videos with 0 distractions and I appreciate that you make them Thank you.
Thank you very much... nice to hear! I appreciate you watching!
Send me your mailing address and I'll send you some of my channel stickers... if you want some.
This video (along with part 2) is amazing! Took me right through a clutch swap in my 06 TDI. Really appreciate the time and effort that goes into sharing a pro's view with the rest of us!
Kind of you to say... many people don't seem to grasp the concept of my point of view videos. Thank you for watching!
Im a 4 year retired vw audi shop owner. And for some reason these keep popping up this week...
Ive done sooooooo many damn clutches. They are a cake walk .
Thanks for the video. I changed the clutch on my daughters car this week, and having the video made it a breeze.
Thank you for sharing your DIY success... and thank you for watching!
Nice job , have to save pat 2 for tonight and popcorn. Love the little guy with the tap,tap,tap and jeopardy ha. I would mind a nice polka once in a while :)
LOL, MC Hammer breaking it down! I'll add polka to my viewer wish list!
Well whaddaya know! This expert guy again paving the way for us curious diyer's and the dabbler's of the innards of our very own VW golf TDI's!!
Thanks I'll be saving the two videos in this particular series to watch later, I'm hearing a slight rattle which o know to be the dmf, it's started recently after letting a local garage change the clutch.. tbf that was around 18 months ago,
However I am leaning toward replacing with a single mass type just to eradicate the obvious flaw the 'improved' dmf is allegedly meant to be.
Cheers mate.
Was the DMF replaced or just the clutch disc & pressure plate?
Removing the DMF will result in transmission gears rattling at idle.
@@EXOVCDS ah ok, think it was just the clutch/friction plate but I'll ask the garage who did it so I'm clear on that, thanks for the reply. 👍
saw the head off a hub/driveshaft bolt, screw back in & use your brake drum/hub puller to force CV joint through :-)
+1973Robski Nice! Will have to remember to make one!
Thanks for posting Thomas , I replacing clutch on 2009 VW Jetta TDI Wagon any tips as have to replace it on my Driveway,
Snap On 3/8" im31A; still kicking, after all these years? Impressive! Not the most powerful 3/8" impact but they did seem, to last a long time! :)
+William Pelzel This one has been overhauled since purchase and has quite the kick back in it... a bit noisy, that's why I don't use it much.
Yeah, the flat rate Snapon rebuild service; can be a good deal. I have the 1/2" version IM51A; my first impact. Now, I have a older plastic body Ingersoll Rand IR-2131; much lighter and more powerful. I was skeptical of the plastic body but now appreciate, the less weight and power. I'm learning to appreciate; IR impacts.
I think my favorite Snapon air tools are my FAR7200 3/8" ratchet (a beast) and my 1/4" FAR25A (fast)! Now my cordless little 7.2V screw driver; is a great way, to speed up the little stuff and fasteners. I highly recommend; all three! :)
Thanks for posting this video, you are doing an awesome work and i like it a lot. I am removing an engine from a passat 09 these days, this engine are going to be charged with a new one, and the gear box is an automatic. Do you have some advice for me, i have never done this kind of work. What is the important thing to think about? Thanks a lot.
If you don't already have a service manual... download it from here:
erwin.vw.com/erwin/showHome.do
Create a free user account and then pay for a 24hr subscription ($35USD).
You can then download as much as you want and the pdf files will not expire (best deal online)!
You need to be sure that you can raise & support the vehicle safely and that you can lower the engine & transmission safely... either together or individually. The torque converter bolt need to be removed so that the transmission can be pulled away from the engine. If it is a DSG transmission, then there are no torque converter bolts (easier transmission to remove).
There's too much to list / suggest. If / when you have specific questions / issues... send me an email (you can also send pictures that way). Click on the fkh161 link in the description and then click on "tool request" to send questions.
Awesome video. You finally got a headlamp! You should check out the Zebralight H602w. MUCH brighter, and a very even distribution of light. perfect for working on cars. Oh, and much longer battery life.
+Jordan Ledbetter Thanks for the tip... the camera can't handle anything brighter though.
Why is the engine light displaying on. It shows clearly on the display on the techs of the car
At what point in the video?
do you have to loosen the axle nut and remove axle. ?
did you lock the shifter before taking off
Thomas-Nice Video thank you! Can you tell me if there's much difference doing a clutch on an 03 MKIV Jetta, or is it basically the same? Cheers,Victor
Here's a 2.0L Golf / Jetta video: th-cam.com/video/XJshGRgU28g/w-d-xo.html
1.8T, 1.9L TDI, VR6 pretty much similar.
Hey, I replaced the clutch in my son's 2008 jetta the same way you did,but it will not crank the battery and starter good I replaced the clutch potion sensor and nothing please help me great video thanks.
Check your ground cable connection at the transmission.
Thomas EXOVCDS I checked all the cables and they are all connected. Its still not doing anything.
Replacing a clutch is mainly mechanical parts, aside from the battery & starter cables. The clutch pedal switch is the only other thing that could be the issue... but why now all of a sudden? It only makes sense that it is related to the starter or battery cables. Manually activate the starter with jumper cables... attach power & ground directly to the starter & battery via jumper cables. Then, trigger the starter by applying power to the starter solenoid (remove the trigger connector to expose the terminal). Starter should turn every time the solenoid is energized. If yes, not a starter problem.
Can you ,please tell me what's the weight of the ALH gearbox for an a3 8l? Thanks 👍👍
I have never checked the weight.. 50 to 100 lbs?
Hi there, I´m about to change my DMF and Clutch on my Golf 5 1.9 TDI, I was wondering if I do need to unmount the Axle nut and exhaust system, would this guide work with my Golf ? Thx
I tend to remove more than I need to... to give me more room to work (in some cases). Remove what you feel is necessary / makes life easier for you.
cool thanks, gona do it actually tommorow xD wish me Luck
Good luck... play / work safe! Let me know if you run into any problems or let me know how things went.
why did you take the selector arm off?? just to get at the bell housing bolt?
So that it does not interfere / get caught on anything when removing the transmission.
You can leave it in place if you like... you can do a lot of things different than what I did. There is always more than one way to remove something.
Thomas EXOVCDS ah I see, I've literally just finished doing the same job and didn't remove but all makes sense...not picking holes just intrigued
Slime always! Great videos! Question. Would this process be similar to a 2008 Volkswagen GTI with FSI motor? Cheers brother.
Similar... yes.
Would this be the same or similar procedure for replacing the clutch in a 2006 2.5L? Thanks!
Yes, standard transmission mounting will be similar on the 2.5L... I'd have to check a manual to be sure (have not yet done one on a 2.5l) but I'm quite sure it will be similar.
Thanks for the reply! I've done lots of clutches in my day but not on a VW 2.5 yet. Just trying to be informed before I dig into it. lol
Hi there, I have a vw golf mk5 1.9tdi 2007 and I was changing clutch kit but when I was tightening flywheel nuts it’s rotate a little bit so do I have to rotate it back before put gearbox back up or it doesn’t need to ? Thanks
Doesn't matter... not a problem. You can rotate the engine as far / as many times as you want.
Thank you very much🍻👍
Did you replace the Dual Flywheel with a single mass since they were prone too failure the dual mass
Yes, only because the customer requested it. The transmission now rattles when it is in neutral and the clutch is not depressed. This is a side effect when switching to single mass. The dual mass absorbs the shocks of multiple injector firings (per cylinder)... that's why we usually only install dual mass.
I always thought with single mass the clutch plate absorbs the shocks when moving from the dual
On older TDI's it is not an issue as much, since the injector only fires 1 time. On the common rail engines, you have multiple injector firings per cylinder, per ignition / power stroke. That puts a lot of vibration into the crankshaft, which gets transmitted into the transmission, when a single mass is used. I was surprised that this BRM engine had a rattle afterwards. Yes, some DMF's fail early, but it's the best design to use on these engines.
Would this be similar to a MK5 Jetta clutch replacement? Thanks!
This Video is mk5 clutch removal / replacement.
How do you verify the old clutch isn't an aftermarket part or a fake original part that contains asbestos?
Asbestos hasn't been used for quite some time... doesn't matter what the old one was, if you order the correct part for what the vehicle requires, you just install that.
Some aftermarket parts do contain asbestos if they are made in China or India if I may believe the internet.
Do I need to flush out transmission oil when replacing the clutch kits and DMF?
No... but changing transmission fluid / gear oil is not a bad idea.
@Razvan Negoitescu I would change it every 60k to 80K km's (37k to 50k miles). Some people change it sooner, some later. Personal preference. I think the dealer maintenance chart says to check every 20K miles and top up if needed.
I have a 2010 tdi jetta 2.0 mk5 6 speed manual, is the video the same as my car?
Short answer: yes
Long answer: Your 6 speed will look different compared to the 5 speed and will have slight mounting differences as well as linkage differences. Here's a 6 speed removal video on an A6/mk6 GTI (which should be similar to your vehicle).
th-cam.com/video/ZGj30dpoNfk/w-d-xo.html
@@EXOVCDS thank you so much for your response even with the video being 5 years old
@@EXOVCDS also do you by chance have a video on how to do a crank position sensor on a car like mine? Its shaped kinda like the letter "z"
No video (yet) sorry.
idpartsblog.com/2017/06/01/default-replacing-g28-engine-speed-sensor-on-common-rail-cbea-cjaa/
Im considering replacing the transmission in my 2006 jetta 2.5l manual 5 speed due to intermittent grinding when going into 5th gear
and the transmission shop believes its due to a synchro. Would this video be similar to doing that task? Also any recommendations on buying a tranny online or should i consider getting synchro replaced? Thank you for making the video
This will be similar to your vehicle... I have a tendency to remove more than need be. 5th gear / syncro can be accessed with the transmission in the vehicle (if I recall correctly) Just the end cover needs to be removed. I'm currently at work... can look for & send you information once I am at home later tonight.
Man i really appreciate . I like the car and would like to hold on to it.
Sorry... got home late. Read through this:
www.myturbodiesel.com/wiki/5th-gear-swap-modification-lower-gearing-on-a-vw-5-speed-transmission/
Thomas EXOVCDS thanks I’m going to give it a try once I find a gear and synchro.
Doing it tomorrow Gt tdi 170 mk5
Let me know how it goes / went. Thank you for watching!
@@EXOVCDS all doneeeeee thaaaaaaaaaanks
@@Boxing-ju1es Thank you for the update!
Hello everyone, is this an bkc engine? The same one as in Volksvagen Touran 2005 with engine code bkc? Thanks
In North America it's a BRM engine... I'm not sure what the exact differences are. I'd have to find service info (since we don't have Touran in North America). It's a PD TDI engine... the BRM).
@@EXOVCDS Thanks man. Hope you find out something
Yes, it is a PD TDI just like your BKC... what is the issue / your question?
@@EXOVCDS Awesome, I was just wondering if I could use this video to fix my car. It got a broken flywheel and turbo.
Should be similar procedure. I can send you some service info for transmission removal and turbo removal. Send me an email and I'll reply once I have found the service info: fkh161 @ fkh161 .ca (no spaces)
is that m14 or m12 triple square bit for flywheel? I need to know since the kit I was looking to buy has 6,8,10 & 12. missing the 9 and maybe 14
+Paul Bilek It should be M12... sorry about that.
+Thomas EXOVCDS no that's OK I'm getting ready to do it the m9 is not in the kit I was gonna get
+Paul Bilek thanks for all the work!
+Paul Bilek 9mm twelve point socket or 6mm triple square bit for the pressure plate bolts (depending on which bolts it has). I'll post a picture later.
+Thomas EXOVCDS OK thanks
What kind of tool is that small air gun your using?
Supreme Lurker The 3/8" air ratchet?
Thomas EXOVCDS i found it thank you. I guess ingersol rand or snapon is the best quality.
+Supreme Lurker Yes...this one is blue-point (cheap snap-on). It makes more noise than it actually is good for. Electric ratchets might actually be more convenient than air ratchet. I'm saving up for electric impact gun & ratchet.
Thomas EXOVCDS absolutely , they come in handy for tight spots . I will look into the electric ones myself. Cheers
Is this a manual transmission?
What's the issue you are having?
I can't help if you don't reply. The title of the video says clutch replacement (as in manual transmission)... watching the video would reveal / show shifter cable removal (standard transmission components).
How come you never worked at a main dealer, Thomas?
None would hire me (fresh out of high school with no experience). I worked for a GM dealership for 6 months as a parts driver... hoping to get into the service department. Had enough after 6 months and started knocking on doors again. Found a couple of Germans running a small VW shop... and the rest is history. :-)
How long have you been at this place for?
+StopDropandLOL 23 years... I'm one of the "oldtimers" now!
Wow! That's cool. Considering I'm only 29, you've been working there since I was 6! :P Love watching your videos, keep it up man they are great.
+StopDropandLOL There're times when I think that I should have moved on (worked at several different places to gain different experiences)... but I don't think I would have been able to accumulate the tools as I have been. I've seen a lot of guys come & go... guess I'm old school, I stick with the place that gave me a shot. :-)
How much time will I need to replace clutch in Golf mk5 1,9 tdi?
I think that the labor guide says around 6hrs... depending on your skill levels, that can be 3 to 4 hrs to 12 or more.
awesome vid
+Sebastian Howard Thank you for watching!
can't you just take it off the transmission and tie it
The more room... the better / easier it will be to work in / with. But as with any repair, not everyone does it the same way.
Hello Thomas, I have got a car exactly like this engine code CFFB and the primary fuel pump that's before the fuel filter in the engine bay is making a serious buzzing , is this normal? It should be like this or the pump is on the go and I will need a new one?th-cam.com/video/O3ORLjrQKw8/w-d-xo.html
Old age, air in the system / cavitation / restriction of fuel from the tank to the pump?
@@EXOVCDS the car is 2010 so this is 9.5 years old, I did change the fuel filter just before the buzzing, so before I take the old filter out I soak the new filter in diesel attached and also filled the filter bottle to the top, and the car started with first turn, I didn't use anything to prime the pump, it might be the small air, but the car would not start with first key. Did you ever meet a situation like this?
No... I always prime the system by running the fuel pumps (before I start the engine). I do this for 2 to 4 minutes before I start the engine. Air in the high pressure pump can cause damage... that's why I always prime with the pumps.
Good job!
thank you for watching!