This weekend was very productive, I was able to get my RSR clutch kit installed thanks to big help from
@CowTownRacer. I'm awful at remembering to take photos when I'm focused on something, so there won't be any. Sorry y'all.
Parts that went in on Saturday:
iAbed Billet RMS
DIY RSR clutch kit
-- Sachs DMFW
-- Sachs A4 Quattro clutch disk
-- Sachs TT-RS pressure plate
aluminum TOB
Spulen billet bleeder block
USP stainless clutch line
Output shaft seals, both sides
Full parts list with P/N
The day started off very efficiently, got pretty much all the accessories off before I managed to cut the back of my hand by smacking it on the bell housing. Pretty good pair of lacerations, almost 1cm across each. I wish I had snapped a photo before it started bleeding because I could see straight through all the skin layers and into some muscle fibers and possibly tendon... it was pretty cool. Matt helped me get all patched up with some closure strips and we kept working.
My original clutch and flywheel were looking very worse for wear, especially the DMFW. You could get the outer section of it to move at least half an inch by applying barely any force by hand. The new flywheel was rock solid.
We had two small hiccups.
1.) It completely slipped my mind that the transmission bracket (for the mount) had to come off in order to slip the bellhousing around the subframe... and all three of those bolts are TTY. We got pretty lucky that the nearby dealership had two of the bolts in stock and Matt ended up having a spare for the third. Good to go.
2.) We started torquing down the pressure plate bolts (which are TTY), when I realized that we hadn't put the thin steel plate "gasket" against the block....... pause. After much deliberation, considering pausing for a day or two in order to get new PP bolts, we decided to just make it a two-piece gasket and we cut it with a wheel. We added some RTV where we cut it in order the restore the "gasket", and away we went.
We ended up working into the night, but everything else went really smoothly. Had every tool we could possibly need.
My impressions on the clutch are great so far. Pedal is much stiffer than stock, maybe 100% more, but we found out my brake fluid was pretty dirty, so that may have contributed. We ended up flushing a bit over a liter while bleeding the system. Clutch engagement is sharp, but refined -- still very easy to smoothly slip into gear. Starting in 1st from a stop feels more confident than before, less chattery. Incredibly glad I went this route. Can't wait for it to be fully broken in so I can step on it a bit more.
Here's a list of all the resources I used to prepare for this DIY.
--
Excellent post by
@Tony48
--
Awesome full DIY by
@T is for TURBO
--
Output Shaft Info over on VWVorttex
-- these two excellent videos by carwerks101 (
vid one, and
vid two)