Chris SGolf syncro clutch replacement
This is not intended to be a step by step guide , more of an oversight so that anyone with a reasonable mechanical knowledge, equipement and a Haynes golf 2 manual nr 1081 can with some help from a friend change there own clutch.
Depending on equipement ,experience and how easily the bolts come undone this job can take anything between seven to ten hours or possibly even longer if you hit snags.
You will need in addition to a socket set, spanners, Haynes manual etc, an engine crane and a trolley jack, these can usually be hired, try looking in yellow pages or similar,
Most (but obviously not all) of the procedures are as described in the Haynes manual and here I am only listing when a different procedure is needed specifically with a syncro .
There are two differing ways to tackle this job, the first is the workshop manual way,which only removes the gearbox and leaves the motor and angle drive in situ, the second is what I think is the easier but longer way and this removes the motor, g/box and t drive in one unit which you then split, replace the clutch and rejoin on the workbench before refitting to the car.
Method 1
Removing only gearbox Step 1 to 3 as book,
4 I would completely remove the battery for safety,
5 as book, go to following page for 020 g/box,
25 drain oil from angle drive as well as g/box,
26 to 32 as book,
33 completely remove starter motor,
34 to 35 as book,
36 also remove the four g/box to angle drive bolts,
37 detach only the left hand driveshaft,
38 to 44 as book, your g/box should now be removed and you can replace the clutch (again see Haynes manual)
refitting
45 THIS NEXT STEP IS VERY IMPORTANT
now molykote the angledrive shaft and fit new clutch seals and bearings p/ns 020 311 108A, 020 311 113, 020 311 107D
Method 2
Removing engine, gearbox and angledrive in one unit
1 to 19 as book,
20 also remove the 3 bolts connecting the g/box rear drive flange to the propshaft,
21 to 40 follow which paragraphs are relevant to your engine
To split the the engine from the box the you can remove the 4 bolts holding the angle drive to the g/box, and/or remove the two bolts holding the angle drive to the bracket on the rear of the motor, the g/box and angle drive will now release from the motor in one piece.
Replace clutch (see Haynes manual)
refitting as book, with the addition of reconnecting the 2 bolts to the angle drive bracket and the 3 angle drive to propshaft bolts.
WARNING
Try to save and reuse your old gearbox oil, as the detergents in the new oil may bugger up your old oilseals and cause them to leak quite heavily, I recomend replacing the the clutch seals as mentioned above as if they leak (as mine did) you will very quickly (in a matter of days)need a 2nd new clutch!