2005-2010 VW Jetta Golf Rabbit MK5 2.5 Manual Transmission Removal Clutch & Flywheel Conversion Tips
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- Опубликовано: 23 авг 2024
- 2005 2006 2007 2008 2009 2010 VW Jetta Golf Rabbit
MK5 2.5 Manual Transmission - 5 Speed - Tips on how to remove and replace the Manual Transmission, Clutch and Flywheel Conversion.
This is a basic overview of what to expect when replacing the manual transmission on a 2005-2010 VW Jetta, Rabbit or Golf 2.5. These 5 speed transmissions are known to have problems if they are driven hard or raced.
When these transmissions are power shifted, they come apart inside and knock a hole in the case behind the clutch, leaking gear oil out of the transmission case and causing the clutch to slip.
This video also applies to Diesel Jetta's and Golf's. They have the same exact transmission (except fitted with taller gear ratios) and bell housing pattern as the 2.5 gas 5 cylinder Jetta's and Golf's. They also have the same size cv axle flanges.
Additional Video Notes:
1. To quickly remove the flywheel, a low power electric impact can be used with the corresponding triple square. I used a snap-on electric impact and it worked great. Use a VW/Audi flywheel lock to hold the flywheel in place when reinstalling the flywheel and torque to spec. These flywheel locks are available on Amazon, Ebay, Google etc.
2. The Subframe does not need to come out of the car in order to remove the transmission. It can remain in place.
3. The sway bar links are often rusty and over torqued, and will need special care to remove. They need to be removed from the bottom in order to get the cv axles out on both sides.
4. The cv axles will come out without having to remove the ball joints or touching the alignment. Make sure the outer axle bolts are removed on both sides, and turn the steering wheel all the way out on the side you are working on. This will allow you enough room to slip the axle out without unbolting the front suspension. Simply unbolt at the cv flanges, lift the axle up in the air, and then pull it away from the spindle.
5. The transmission is a carryover unit from the 2.0/diesel MK4 Jetta's and Golf's. It is almost identical to the 02J transmission. The only difference is, the mounting points for the shifter bracket are different, and the MK5 does not have the speed sensor on it (MK5 calculates speed through abs sensors). IMO, the original stock MK5 transmission is not made for the extra weight and torque of the MK5 2.5 VW's.
6. MK5 5 speed transmissions are hard to find! They are usually picked up very quickly at the u-pull its, and are very expensive to purchase on ebay. They usually cost between $900-$1700 on ebay. This is due to many of these transmissions failing early due to the weak design. Mk6 5 speed transmissions can also be used, but are also hard to find. They can be found on the MK6 2.0 models.
7. A MK4 transmission can be made to work in a MK5, but it is not recommended. The shift cable bracket will need to be modified in order for it to work, and the gear ratios will be incorrect. A MK6 transmission would be a better alternative if no Mk5 transmission is available.
8. A Bentley, Haynes or Chilton Manual are highly recommended for this job. They all contain valuable reference material as well as all of the torque specs that will be needed to put everything back together. They can all be found on Amazon or Ebay.
9. When the cv axle flanges are removed in order to remove or install the transmission, some gear oil will be lost. The total gear oil capacity of the transmission is 1.9 Liters. It can be topped off by adding some gear oil through the switch at the top of the transmission. Remove the switch with a 22 mm socket, and using a siphon tube, add the proper amount of gear oil to the transmission.
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Hey I’m stuck taking the trans off the engine I have all the bolts off I can see between the engine and trans so I know all the bolts are off but it won’t seem to come off do you have any tips?
Make sure everything is unhooked around the transmission, including accessories, cables etc. Make sure both CV axle flanges are removed, as well as the outer transmission support bracket at the tail of the transmission. Use a large pry bar to slowly pry the transmission away from the engine block. You can tell you are making progress when you can start to see the flywheel and pressure plate. Have a helper work the prybar back and forth as you break the transmission loose. Use a transmission jack to help drop the transmission. It will slowly come out.
Is there any pros to using a solid over a dual?
The solid flywheel is cheaper than the dual mass, and can be resurfaced easily. The dual mass flywheel is very expensive, and is not supposed to be resurfaced, so it would be more expensive to keep up and maintain. Also, the clutch discs are different, solid vs dual mass. The clutch disc that matches with the solid flywheel is a traditional style disc, making it an inexpensive replacement part.
How the hell do u get the stub shafts out for the axle on the transmission? I’ve been fighting this thing
Once you take out the axles, look in the center of the stub shaft. Clean the grease out of the center, and you will see the small plastic cover. Pry the cover out to reveal a small allen hex head bolt. Remove it with an allen head socket. It is not torqued in very tight, it will come right out. You can then remove the axle stub/flange. Just pull it straight out. Be careful not to lose the compression spring on the back of the axle stub. Installation is the reverse. Put the axle stub back in, and torque the allen head bolt back into place.
Now I know no to power shift annymore learn that the hard way…😂😂 Also I’m a machinist so I was thinking about resurfacing the flywheel and putting a new clutch and pressur plate. If I do that should i go for the clutch with a diaphragme or coil spring? I’ve search quite a bit and found opinion’s that went on both side.
You have two options. You can reuse the original dual mass flywheel, resurface it, and purchase an original style diaphragm clutch disc and pressure plate. The diaphragm clutch disc will only work with an original style dual mass flywheel. Your second option is to purchase a solid flywheel conversion kit online. The conversion kit uses a solid flywheel and a spring type clutch disc, and this spring type clutch disc will only work with the solid flywheel that comes in the kit. Diaphragm clutch disc = Dual mass flywheel. Spring clutch disc = Solid flywheel.
@@rollingjunk perfect I understand now for the clutch Huge Huge thanks! I really appreciate it.
I also wonder if the hole in the transmission can be weld up so I can use it again but not have the problem of oil going on the clutch. If it’s possible I would tape a nut in the bottom to drain the fluid and replace it.
Sorry for my english, it’s not my first language. Thanks a lot for your video and have a great rest of the week-end ✌🏽
@@MAGCARS you may be able to weld it up, but the gears inside may not be any good from coming apart through the case. Good luck!
@@rollingjunk thank you😅