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  1. #1
    Active Member Two Rings Jarrodg1993's Avatar
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    What Else To Do When Changing Tranny

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    Ok so I'm getting ready to put a new transmission in my 02 a4 quattro 1.8t. My second gear is jacked and I'm done only having 4 gears. I plan to also do the rear main seal and the pilot bearing while I'm in there. It already has a newer clutch that works great. What else should I do while I have the trans out of the way?

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  2. #2
    Veteran Member Four Rings Spike00513's Avatar
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    Quote Originally Posted by Jarrodg1993 View Post
    Ok so I'm getting ready to put a new transmission in my 02 a4 quattro 1.8t. My second gear is jacked and I'm done only having 4 gears. I plan to also do the rear main seal and the pilot bearing while I'm in there. It already has a newer clutch that works great. What else should I do while I have the trans out of the way?

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    I have a spare but it's a 6-speed. If you could use any parts from it.
    However, maybe they share some parts? Such as certain gears.

    Brand new, or new to you?

    02 1.8T would be 5spd. 04-05 is 6.

    I wonder how it happened, and why 2nd.

    Well, rear main seal is accessible. As are other things like pilot bearing.
    I'm thinking...
    Well for starters, have you ever done a rear main? It's tricky. Takes being careful to get the PTFE seal right. I only did it on a 3L before though, not a 1.8T. And used a cut up soda bottle as an install tool.

    Hoping to come back later with more info/answers.

  3. #3
    Veteran Member Four Rings gmudan's Avatar
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    Throw out bearing, and maybe the slave cylinder because its easy to make sure its properly set when the transmission is off.

  4. #4
    Veteran Member Four Rings jjvwg's Avatar
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    I would not touch the rear main seal unless there is reason to change it due to leaking.

  5. #5
    Senior Member Three Rings Gin+'s Avatar
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    Quote Originally Posted by jjvwg View Post
    I would not touch the rear main seal unless there is reason to change it due to leaking.
    I agree with this guy.
    They're not scared of you. They're scared of what you represent to 'em.

  6. #6
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by Spike00513 View Post
    I have a spare but it's a 6-speed. If you could use any parts from it.
    However, maybe they share some parts? Such as certain gears.

    Brand new, or new to you?

    02 1.8T would be 5spd. 04-05 is 6.

    I wonder how it happened, and why 2nd.

    Well, rear main seal is accessible. As are other things like pilot bearing.
    I'm thinking...
    Well for starters, have you ever done a rear main? It's tricky. Takes being careful to get the PTFE seal right. I only did it on a 3L before though, not a 1.8T. And used a cut up soda bottle as an install tool.

    Hoping to come back later with more info/answers.
    New to me. It's was only $350 and it works. Couldn't afford to get a new or rebuilt one. I wish I could put a 6 speed in but I've heard there are more modifications required, that I want to make to this car. Thanks for the offer though. Apparently (according to the shop) the synchros go bad on these transmissions regularly. I guess 2nd gear was the one that decided to go first? It won't fully engage 2nd gear.

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  7. #7
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by gmudan View Post
    Throw out bearing, and maybe the slave cylinder because its easy to make sure its properly set when the transmission is off.
    Thank you, I will look into these

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  8. #8
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by Gin+ View Post
    I agree with this guy.
    Why do you guys say this? Just curious. I know it's something that goes bad on high mileage cars and I figured I'd do it while I was in there. Didn't look too difficult from that research I did but, I could be gravely mistaken. Please elaborate

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  9. #9
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by jjvwg View Post
    I would not touch the rear main seal unless there is reason to change it due to leaking.
    It was recommended to me by an older mechanic but after doing research into it, I see that you are very right for this car. Apparently, most people cause a leak to happen when they didn't have one before because theses seals are a PITA to install correctly... I will be leaving the old one in there as it is not leaking..

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  10. #10
    Established Member Two Rings jj94tt's Avatar
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    Quote Originally Posted by Jarrodg1993 View Post
    What else should I do while I have the trans out of the way?
    If your car is equipped with a dual mass flywheel and it was not replaced when your "newer" clutch was installed, I would definitely replace that. They do wear out. My new flywheel came with a new pilot bearing installed, too. Mine started a nasty vibration at 110k miles.

    If the car has been converted to a solid flywheel, you are good to go. In fact, if you aren't doing anything with the flywheel, that's another good reason to leave the rear main alone (if it's not leaking). Once you remove the flywheel, you would have to get new bolts and torque them properly, to do it right.
    2005 A4 B6 3.0L 6MT USP Ocean Blue

  11. #11
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by jj94tt View Post
    If your car is equipped with a dual mass flywheel and it was not replaced when your "newer" clutch was installed, I would definitely replace that. They do wear out. My new flywheel came with a new pilot bearing installed, too. Mine started a nasty vibration at 110k miles.

    If the car has been converted to a solid flywheel, you are good to go. In fact, if you aren't doing anything with the flywheel, that's another good reason to leave the rear main alone (if it's not leaking). Once you remove the flywheel, you would have to get new bolts and torque them properly, to do it right.
    Ok thank you. How do I tell if the flywheel is worn out?

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  12. #12
    Established Member Two Rings jj94tt's Avatar
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    Quote Originally Posted by Jarrodg1993 View Post
    Ok thank you. How do I tell if the flywheel is worn out?
    If you place your hands at opposing sides of the disc, say 3 and 9 o'clock, and attempt to rock the disc, there should be no motion in that direction. Also, there is a spec to how much the two masses should rotate with respect to one another... not sure what the limit should be, but the new one only rotated freely a 1/4" to 1/2" or so.
    2005 A4 B6 3.0L 6MT USP Ocean Blue

  13. #13
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by jj94tt View Post
    If you place your hands at opposing sides of the disc, say 3 and 9 o'clock, and attempt to rock the disc, there should be no motion in that direction. Also, there is a spec to how much the two masses should rotate with respect to one another... not sure what the limit should be, but the new one only rotated freely a 1/4" to 1/2" or so.
    Ok thank you. Would this info be in the Haynes or Chiltons? I have them both.

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  14. #14
    Veteran Member Four Rings SJorge3442's Avatar
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    Quote Originally Posted by Jarrodg1993 View Post
    Ok thank you. How do I tell if the flywheel is worn out?

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    Here is a video I made when I replaced my failed DMF.
    2003 3.0 6 Speed - Quattro. 151k.

  15. #15
    Veteran Member Four Rings Gosser's Avatar
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    Just doing a clutch my self. Looked at the rear main seal and decided to leave it as is for all the reasons listed above. I replaced the input, flange, output and shift rod selection seals. Only the rod selector was leaking but did them all anyways. Also did the metal slave cylinder, throw out and pilot bearing. Did the fluid with new plugs. I should have done the throw out lever plastic pivot point but didnít have time to wait for it. Iím sure itíll be fine.

  16. #16
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by SJorge3442 View Post
    Here is a video I made when I replaced my failed DMF.
    Hmmm... Would this cause a vibration in the clutch pedal even when the clutch is completely disengaged? And by disengaged, I mean that the pedal is pressed all the way down.

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  17. #17
    Veteran Member Four Rings SJorge3442's Avatar
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    Quote Originally Posted by Jarrodg1993 View Post
    Hmmm... Would this cause a vibration in the clutch pedal even when the clutch is completely disengaged? And by disengaged, I mean that the pedal is pressed all the way down.

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    Absolutely. That's when mine felt the worst. Especially if I revved the motor above 1K. Think about it for second. When you press the clutch, you're putting an extreme amount of pressure on the pressure plate, thus you're also pressing against the flywheel. If the bushings are shot in the DMF like mine were, when you press the clutch, the whole rotating assembly is now off balance even more. There was a sweet spot (i think) where i could find an RPM where I wouldn't have a shake/vibration, but it was very narrow. Gotta remember, that flywheel is 20+ lbs, so when its off balance due to failure, you're gonna feel it. I have a 3.0 so my motor is inherently a little more balanced, but on a 4 cylinder, you're gonna feel it a little more since the motor isn't as self balancing as a V shaped motor.
    2003 3.0 6 Speed - Quattro. 151k.

  18. #18
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by SJorge3442 View Post
    Absolutely. That's when mine felt the worst. Especially if I revved the motor above 1K. Think about it for second. When you press the clutch, you're putting an extreme amount of pressure on the pressure plate, thus you're also pressing against the flywheel. If the bushings are shot in the DMF like mine were, when you press the clutch, the whole rotating assembly is now off balance even more. There was a sweet spot (i think) where i could find an RPM where I wouldn't have a shake/vibration, but it was very narrow. Gotta remember, that flywheel is 20+ lbs, so when its off balance due to failure, you're gonna feel it. I have a 3.0 so my motor is inherently a little more balanced, but on a 4 cylinder, you're gonna feel it a little more since the motor isn't as self balancing as a V shaped motor.
    Hmmm.... I'm wondering if this is the vibration I feel though the whole car.. I have done a lot of things to eliminate the vibration and the motor runs really smooth, quiet and strong but, there is still a vibration with it that I feel through the entire car... Might be the issue, might not. I'll go ahead and order a flywheel to have on hand in case I need it. If not, I can always return it but, chances are I'll need it. Now I just need to figure out what kind of flywheel I need..

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  19. #19
    Active Member Two Rings Jarrodg1993's Avatar
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    Any recommendations for the type of flywheel to go with?

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  20. #20
    Established Member Two Rings jj94tt's Avatar
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    Quote Originally Posted by SJorge3442 View Post
    Absolutely.
    Agree with this. Having no prior experience with a DMF, I was surprised how noticeable it was.

    I just went with a new LUK dual mass (OEM replacement) from RockAuto (selected for cost - FCP has warranty, but is more $) for my 3.0L, mainly because I just wanted it back to the way it was. I think 1.8T has many more clutch options with lots of user feedback.
    2005 A4 B6 3.0L 6MT USP Ocean Blue

  21. #21
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by jj94tt View Post
    Agree with this. Having no prior experience with a DMF, I was surprised how noticeable it was.

    I just went with a new LUK dual mass (OEM replacement) from RockAuto (selected for cost - FCP has warranty, but is more $) for my 3.0L, mainly because I just wanted it back to the way it was. I think 1.8T has many more clutch options with lots of user feedback.
    Ok, how do I know if I need a solid or if I can use a DMF? Can I just put a DMF in even if the one in there is a solid one?

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  22. #22
    Veteran Member Four Rings SJorge3442's Avatar
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    Quote Originally Posted by Jarrodg1993 View Post
    Ok, how do I know if I need a solid or if I can use a DMF? Can I just put a DMF in even if the one in there is a solid one?

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    You can use whatever you want as long as its mounting surface is the same as the clutch disc. Most people seem to go with a SMFW, others like the Lightweight. Search around a bit (Theres even a clutch chat happening a couple posts down) and see what will best suite your needs. If you're car is stock or mostly stock, I'd stay on the more mellow side of things in regards to the clutch. Don't want a chatter-y car that cant get out of its own way, right?
    2003 3.0 6 Speed - Quattro. 151k.

  23. #23
    Established Member Two Rings jj94tt's Avatar
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    Quote Originally Posted by Jarrodg1993 View Post
    Ok, how do I know if I need a solid or if I can use a DMF? Can I just put a DMF in even if the one in there is a solid one?
    -EDIT- Please correct me if I am wrong... maybe I didn't research this thoroughly enough.

    You can't switch flywheels without changing the clutch disc and pressure plate as well. Consider those three items as a package: you can have a DMF package or a solid package. You'll have to see what you have when you disassemble, if you don't already know. If you do have a single mass (solid) flywheel, you don't have to do anything since the clutch and pressure plate have already been changed to suit.
    2005 A4 B6 3.0L 6MT USP Ocean Blue

  24. #24
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by jj94tt View Post
    -EDIT- Please correct me if I am wrong... maybe I didn't research this thoroughly enough.

    You can't switch flywheels without changing the clutch disc and pressure plate as well. Consider those three items as a package: you can have a DMF package or a solid package. You'll have to see what you have when you disassemble, if you don't already know. If you do have a single mass (solid) flywheel, you don't have to do anything since the clutch and pressure plate have already been changed to suit.
    I believe its a DMF. The car is completely stock except the radio and sub lol I think I'll stick with the DMF for comfort?

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  25. #25
    Active Member Two Rings Jarrodg1993's Avatar
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    Quote Originally Posted by jj94tt View Post
    -EDIT- Please correct me if I am wrong... maybe I didn't research this thoroughly enough.

    You can't switch flywheels without changing the clutch disc and pressure plate as well. Consider those three items as a package: you can have a DMF package or a solid package. You'll have to see what you have when you disassemble, if you don't already know. If you do have a single mass (solid) flywheel, you don't have to do anything since the clutch and pressure plate have already been changed to suit.
    It was a DMF that was burnt up along with a clutch and pressure plate that were burned up. Replaced all that and the bearings and she rides like a totally different car now!

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