Gearbox Clutch CVs - Diesel Uprated Clutch

Whatever diesel you put in your T25, you're usually stuck with the original fit 1.6 flywheel and clutch.
Once you start upping the power, particularly of the 1.9 TD or Tdi, you can experience slip, particularly
between gear-shifts.

andysimpson: An update to the clutch fix.

Had a new flywheel Part no:028 115 269B Was fitted to Mk3 golf/vento/passat tdi's, golf g60's, various passat petrols from 88-96. It weighs aprox 9.5kg. This is a different shape than the JX flywheel in that it has a large 2"band of extra weight on the engine side that fouls the metal plate between enigne and gearbox, this needs 16mm maching off to match rough dimensions of the JX wheel. Taking off the 16mm also brings the weight down to just below the JX wheel of 6.5kg. This is not as drastic as it sounds, its still just as thick as a JX wheel.

New cluch pressure plate Part no:021 141 025F or FX if your dealer is daft enough to take a 1.6 one in place (hint leave it very very dirty, they won't touch it to look for numbers, they do not want oil under their finger nails or on their white shirts) Was fitted to 2.8/2.9 VR6's and some 5 cylinder tdi's. There are other plates that will bolt onto the flywheel, mainly tdi ones but this one has the highest holding pressure. This needs 1 locating hole enlarging by aprox 2mm.

New clutch disc Part no:025 141 031K or KX if your dealer is daft enough to take a 1.6 one in place (hint leave it very very dirty, they won't touch it to look for numbers, they do not want oil under their finger nails or on their white shirts) This is from a waterleaker. No mods to this, it matches the gearbox splines and is the correct diameter.

New bolts for pressure plate to flywheel, there different to JX ones. Part no:N 101 010 01 you will need 6 of them.

If your dealers take back the old 1.6 bits as exchange it will cost around £290+vat+machining. This is the cheapest way of doing it and the most sensible, everything is geniune vw not cheap nasty stuff. It you break it you can go to your local dealer and get a replacement bit and your not getting someone is germany or the US to make a replacement in their garden shed.

This set up is the only one that is going to keep a syncro bell housing water tight.

The only down side is you loose your timing marks so it would be good idea to change cam belt and check timing before changing clutch. _________________

angry vanagon:

I have the same set up in my 1.9tdi panelvan but i also machined off the shoulder to the rear of the starter motor ring gear so the starter nose/end suport bearing did'nt fowl the flywheel and there where two tiny lumps sticking out on the pressure plate that fowled the inside of the gearbox that had to be removed.

1 photo of pressure plate tab's to be removed

2 photo of pressure plate tab's fouling on diesel bell housing

3 photo of machining on 02A flywheel to clear starter motor nose support bearing casting

Hope this helps andrew