G60 Clutch job

I've done it very recently so it's still fresh. It's the toughest clutch job I've ever done as there is no room to maneuver the tranny. It's nothing like a rabbit clutch job:

1. Loosen axle nut on driver side while car is still on the ground.

2. Remove battery.

3. Disconnect wires from starter and remove starter.

4. Jack up car very high and put on jack stands because.

a. You'll need the jack to lift the engine.

b. You'll need enough clearance to pull the tranny when it's dropped.

5. Remove 1 intercooler tube (Intercooler to Tbody).

6. Unbolt slave cylinder from top of tranny bell housing and tie up.

7. Unbolt shifter cable assembly from shift linkage on top of tranny and tie up.

8. Remove lugs and remove driver side wheel.

9. Unbolt the 6 bolts (8mm 12point spline)from cv to differential on each side.

10. Remove drive side axle.

11. Support engine w/jack (and some padding of course).

12. Unscrew speedo cable from top (towards the back) of tranny.

12. Remove 3 top bolts on passenger side rear mount.

13. Remove top bolt on driver side rear mount.

14. Remove driver side mount (2 bolts).

15. Remove driver side mounting from tranny.

16. Remove 2(3) bolts holding cover to bottom of engine/bell housing.

17. Tranny can now be pulled and dropped. There is a hook that is strategically placed on the tranny to chain a cherry picker to. But, you can pull the tranny off by hand.

18. G60 clutch:

a. The 6 pressure plate to flywheel bolts come off easy.

b. The 6 flywheel to crank bolts I had to blow off w/ an impact.

c. These are stretch bolts so they should be replaced.

d. New disc and pressure plate ran ~$300.

19. Standard resurfacing on the flywheel costs $45 hre in CA, I paid $125 to take off 10 of the 20 lbs. and had it balanced and resurfaced. It makes it a little more fun and revving the engine emmits an interesting jet whine.

20. Take of the sheetmetal plate and change the crankshat seal.

Re-install is in the reverse. I had a cherry picker and felt that I absolutely needed it to position the tranny to mate with the engine whereas with the A1s I could just bench press it on. On the G60, there is no room to move down there.

Only special tool was the 8mm 12point spline bit for the CVs.

Did I miss anything?

Hope it works for you. It's not going to be fun.

-Qui Le

'90 Red G60 w/ Autothority Stage III

'90 Jetta GLI/ 16V stocker

'80 Yellow Rabbit Convertible w/ 1.8L 8V, 80mm AFM, 270 cam,9.5:1, Audi TB (Project back in progress for summer '98), big bumpers, A2 front end,etc.
http://home.earthlink.net/~radog60

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