Clutch Job from hell.

[97 gst turbooo]

Well during my clutch swap i ran into mutilpe problems.One being the axles rusting into the hub assembly. Lower ball joints,upper ball joints,lower laterial arm,staybizlier link,and rotors and pads all were junk. So this is how to i had to remove the axle from the hub.

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And tranny all freshly powdercoated with quailfe lsd.

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Life will be much easier now since its all new and loaded in antisezee.
Car only has 72k never seen this before, Thanks to new england.

 

[95burgundyesi]

For my AWD 2g, all I need to do it remove the upper control arm nut and the 10mm bolt on the brake line bracket. This gives me enough play to pop the axel out and havea buddy turn the wheels while get it out. Buddy just makes it easier.

My car is a Michigan car and my axels are stuck in the hubs. I accidently lowered and bolted my trans and block during the 6 bolt swap with the passanger axel under the trans! So I ahd to cut the boot since it was rusted in the hub.

 

[95burgundyesi]

Also, when removing the upper control arm, make sure to jack it up a hair to keep pressure off the nut as it loosens. Other wise the arm will push on the nut and the ball joint will spin and become a pain in the butt. IF it does happen, use vice grips to clamp on ball joint shaft, then it will spin around eventually hitting the spring.

 

[97 gst turbooo]

Yea i replaced all ball joints and everything in the front end suspension is brand new. The axles couldnt even be smashed or pulled out. So oh well cut the axle and had to plasma cut the hub out. Thats all done now i just finished bolting up the tranny and subframe. Hopefully finish it off tomorrow.

 

[95burgundyesi]

Yeah, well I hope you have good luck, I can do a 2g awd in 2 and a half hours not rushing. Not exactly fast but once you do it its just nuts and bolts, just watch out for the transfer case trying to get ya if your awd .

If I ever break an axel I will need new hubs its like rust welded together.

 

[97 gst turbooo]

Yea have fun, mine ended up having to cut the axle, then use the plasma cutter to cut the end hub of the axle off then just smash the old hub with melted/rusted axle still in the hub. Luckily i have all the right equipment to get it done but no transfer case yet. im still gather all my swap stuff together.

 

[fwdmaster]

Good looking tranny

 

[meliketoball]

I love California climate.

 

[JusMX141]

We recently changed the front wheel bearings in my buddy's '95 TSi AWD during a clutch install.

Took a 20-ton press and LOTS of heat to get the axles out of the old hubs.

 

[92AWDHX40]

Nice looking trans.

 

[97 gst turbooo]

Well bad news today install the tranny and axle buttened it up to find that it wont disengage right. even with a extended rod no luck. thinkin its a tob problem or fork we will see when i drop the tranny tomorrow any suggestions?

 

[JusMX141]

Before you do all of that, play with the adjustment on the pedal a little.

We ran into a similar problem with my buddy's car....when the clutch was adjusted properly at the pedal, the engagement was really high on the pedal and if you pushed the clutch to the floor, the car wouldn't go in gear when it was running. It was almost as if the clutch pushed in TOO far and the pressure plate was hitting the disc.

We adjusted the clutch with more freeplay at the pedal than recommended, and it worked fine.

 

[97 gst turbooo]

well the car just hit 72k so for the 80 bucks i spent on the slave and master cylndier im not complaining. It wont hurt the car by replacing them hopefully that will fix the problem. Damn act 2900hd pressure plate.

 

[JusMX141]

You have a 2900 on a FWD?

 

[Semprini]

For my AWD 2g, all I need to do it remove the upper control arm nut and the 10mm bolt on the brake line bracket. This gives me enough play to pop the axel out and havea buddy turn the wheels while get it out. Buddy just makes it easier.

My car is a Michigan car and my axels are stuck in the hubs. I accidently lowered and bolted my trans and block during the 6 bolt swap with the passanger axel under the trans! So I ahd to cut the boot since it was rusted in the hub.

This passed week I swapped out a transmission and thats how I pulled the axels. I didnt even attempt to remove them from the hub, just pulled the control arms out, and the that gave enough room to pull the axels out of the trans\

You have a 2900 on a FWD?

I have a 2600 on a FWD, is that frowned upon?

 

[JusMX141]

Not really, but wouldn't you think a FWD would spin the tires well before it would attempt to slip anything larger than a 2600 no matter how much HP you're putting down?

 

[97 gst turbooo]

Well now im a master at tranny jobs, haha 20mins to remove everything an drop the tranny. I fixed the clutch problem, who knows what it was but new master and slave cylndier fork and pivot ball replaced made it all better. Bolted it all back up tonight so tomorrow is put the tires and bleed the new brakes. The only reason i went with the 2900 is i am in the process of building up a new 2.0 so hopefully puttin somewhere around the 6's with new turbo setup in the spring. Have to represent fwd!... for now at least..

 

[wishnfor4g63T]

Wish you lived close to me! A shop doing my clutch install has me in a real PITA. Seems A tranny shop doesn't really know how to dsm's in WV. hah well anyhow glad you got your clutch problem figured out Good job on the FWD!

 

[97 gst turbooo]

Yeap checked it out today everythings working awesome. Just need to put the tires on and finish fabbing up my intercooler piping hopefully done tomorrow. Oct.4 we will see what it pulls at New England Dragway

 

[ShawnsGarage]

Looks like you had fun. Glad you got you problems fixed. Car is SEXY

 

[16g-2ndgen]

damn it took me 8 hours to pull my 1g's awd tranny. didnt run into any problems either. i take my time!

 

[ShawnsGarage]

damn it took me 8 hours to pull my 1g's awd tranny. didnt run into any problems either. i take my time!

8 hrs to remove?? Was this your first time or was there breaks every 5 min?

 

[97 gst turbooo]

Wow now that nothings rusted its wicked easy to remove. Like 20 bolts, pop the axles,pull the starter drop it down. Wicked simple on a 2gb gst. I dont know about awd..yet