Transmission challenge

[talon2gbuyer]

Hey all So ive finally gotten into ordering a new FWD trans for my 95 tsi. Ive been scouring the forums looking for a good How-to video and came across something on youtube from jafromobile that is like a 9 part trans/clutch how to. Has anyone used this vid series before? Is it helpful to you? also, does anyone have a definitive list of tools/parts needed for this job? This is my DD so It will be out of commission while I do this repair. Here is what I'm looking at so far.. please add to this so that I do not have any "oh shit" moments and realize i dont have something I need!
I also do not have access to air tools, does anyone see me having an issue with this?

used trans from dsmjunkyard
ACT 2400 clutch and PP
( comes with Press plate, throw out bearing, ect)

Let me know!

 

[russ96gst]

Thats the video I used a couple months ago, I had never done a transmission job before, and that video was a god send! He does a great job explaining, plus the high speed video is nice. I did it all with standard hand tools, a motorcycle jack, (found this easier than using a car floor jack, as it has a larger surface) one thing, when trying to put the transmission in (I did this all by myself, start to finish) I found it difficult to use the jack to align up the trans, so I had to get creative. what I did was, jack the transmission up as close as possible to where it needs to be, then I took a 1/2" pipe that fit from the firewall to the front bumper, 2 ratchet straps, hooked them to the trans, front and back, and was able to "fine tune" it position, took about 10min to get it in this way, (I struggled for a couple of hours with just the jack) Hope that helps and good luck! (its really not that bad)

 

[talon2gbuyer]

sweet, anything else you can think of?

 

[turboglenn]

Hey all So ive finally gotten into ordering a new FWD trans for my 95 tsi. Ive been scouring the forums looking for a good How-to video and came across something on youtube from jafromobile that is like a 9 part trans/clutch how to. Has anyone used this vid series before? Is it helpful to you? also, does anyone have a definitive list of tools/parts needed for this job? This is my DD so It will be out of commission while I do this repair. Here is what I'm looking at so far.. please add to this so that I do not have any "oh shit" moments and realize i dont have something I need!
I also do not have access to air tools, does anyone see me having an issue with this?

used trans from dsmjunkyard
ACT 2400 clutch and PP
( comes with Press plate, throw out bearing, ect)

Let me know!

I'v recently posted a lot of threads on my own trans rebuild and install and the method i used (hoist = easiet ever) I use to drad dropping the trans, with a hoist i'll jump right in, no chance of ruining the clutch disk by hanging the trans from it (well small chance anyway) and much easier to line up than on a jack and i have a floor jack, motorcycle jack and tranny jack attachment and they all suck compared to a hoist.. I won't re-type the same threads over and over so look for anythread on the first page of the drivetrain area in 4g63 tech by me about tranny work, lots of good tips

Glenn

 

[pauleyman]

Flywheel bolts are tough without air tools. If you're getting a new flywheel check the step height. I've said this dozens of times over the years. I don't care if it's brand new out of the box, check the step height anyway. It's the ONLY way to be sure it's right. If you're not sure how take it to a machinist. You will need a depth mic. Caliper will not do.

 

[talon2gbuyer]

Good deal, thanks glenn!

 

[luv2rallye]

When you remove transaxle bolts stick them through a piece of cardboard with a circle drawn on it (representing the housing) so you'll know which went where - like this: http://www.dsmtuners.com/forums/attachment.php?attachmentid=90081&d=1228941528.

You don't have to remove the axels from the hubs at all. You also don't have to remove ANY ball joints! See here: http://www.dsmtuners.com/forums/newbie-forum/316646-pulling-transmission-tomorrow.html#post151688536.

A hoist is obviously the easiest thing but most people don't have access to one or can't afford one. If you use a floor jack to drop tranny use one with the big cup on it (6.5"). Get a helper with lifting/balancing tranny on the jack while taking it out and putting it in. An inexpensive jack that works well (http://www.dsmtuners.com/forums/attachment.php?attachmentid=97194&d=1247441790). eBay has this 450lb scissors cradle tranny jack used for $35 (a new Central Hydraulics one was at Harbor Freight for around $83 item #39178-9VGA). This scissors jack used with an air gun becomes a power lift for the tranny!

I've found the tranny attachment you can get for the end of a floor jack doesn't work well (can't move & twist tranny around which you have to do to install it). There are specialty tranny jacks that do this but they are expensive and not worth a one time replacement.

Another step by step instructions: http://www.dsmtuners.com/forums/articles-drivetrain/59658-2g-clutch-flywheel-installation.html.

Make sure clutch fork is in correct position immediately after you have tranny mounting bolts in or you will be taking it out again to shim the pivot ball: TRE TECH TIPS.

And most of all, take your time to do it right.

 

[talon2gbuyer]

wow nice tips rally, i'll definitely make a cardboard layout for the bolts. Getting kinda excited about this, been quite a while since ive delved into a project like this. Now as for the hoist, If i can get an engine hoist would that d the trick? I can find them used on craigs list for like $80 all day long. The only scissor jack i found on ebay was 400$ for a uni cradle #44 E series. , no thanks, that damn thing is almost as much as my trans will be. On the plus side, when its done i'll have a spare tranny for me to tear apart and figure out how it works

 

[russ96gst]

Yes engine hoist would work great, not as cheap as my ratchet strap method, but will come in handy down the line, cardboard cut out is a great idea, helped me out alot, also make SURE your dowel pins are there when putting your trans back on. you will regret it if you dont!

 

[luv2rallye]

Flywheel bolts are tough without air tools. If you're getting a new flywheel check the step height.

YES!!! Step height MUST be correct for ANY clutch/pressure plate to work properly (otherwise you'll be misled as to the problem) - new or used! So check it now. Here is how to measure step height: RRE's Clutch And Flywheel Tech Info.

Flywheel bolts can be removed with ordinary 1/2" racket/breaker bar if you prevent the flywheel from turning at all (no give what so ever) (eg. wedge something in the teeth). Make sure you use a torque wrench when putting it back on (98 ft.lbs star pattern).