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Old 08-03-2006, 07:58 PM
Jorge R Jorge R is offline
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Re: '96 Jetta GL Clutch replacment...how difficult?

I replaced my clutch and transmission and it was not so bad a job. What you need is to have all the replacement parts on hand and the tools to do the job with.
It is recommended to replace the drive flange seals, they tend to leak, and replace the tranny main drive shaft and clutch rod seals, it is recommended. For the engine, you may want to replace the rear main seal, not difficult to do.
New flywheel bolts will be required for they are stretch bolts and require replacing.
Changin alll the seals and clutch can take me about 12 hours, replacing the clutch only can take you about 10 hours. I would say a day and a half.
Tools needed is an engine hoist or engine support bar, torque wrench, bailing wire to hold the drive shafts out of the way, jack stands, floor jack.
To replace the drive flange seals, a 1/4" by about 6" thick steel bar with holes drilled is needed and bolts and nuts that fit the drive flange to extract and reinstall them.
I found the most difficult part of the job was rounding up all the tools and negotiating the transmission in and out of its place. I replaced the clutch and transmission first, then replaced the transmission again cause it was faulty, did the basic job twice, replacing the transmission only took me about 8 hours. Replacing the clutch and tranny along with all the seals involved was about 18 hours. My skill level with no VW experience as do it yourself mechanic. It was a process but enjoyed the experience. An assistant can come in handy at times.
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