Re: How to: Replace Clutch in '04 Coupe
Removing/Replacing Flywheel, Disc, Cover
24. Lock flywheel with special tool 9102 (link)
25. Remove and discard the flywheel bolts, new ones should be used as torque pressure is too great to reuse old bolts.
26. WARNING: Heavy! Remove dual mass flywheel, had to use rubber mallet to loosen from crankshaft. Remove special locking tool. I also hammered out old/destroyed pilot bearing with hammer and socket. I replaced the bearing with the new one provided in the LUK 11-040 Clutch Rep Kit by banging in a new one using a similarly sized socket. Probably better to use some kind of bearing press for this.(link)
27. At this point I noticed my rear end cover was leaking, rather than replacing both the cover and rear seal I opted to tighten cover bolts and reinstall old flywheel. (Service manual states: The rear crankshaft oil seal cannot be replaced separately. The end cover and seal must be replaced as a set.) It also states you should use “Loctite 5203 sealer” as a gasket for the end cover, which was very hard to find and not cheap. (link)
28. Clean flywheel surface to remove debris. Scuff old flywheel with 180 grit disc to remove glazing and prep for new clutch disc. Clean out debris from sanding, I think brake cleaner is recommended.
29.Replacing flywheel is a *****, its heavy and tight fitting and hard to get into position. Once I finally got it lined up properly, I used a rubber mallet to bang it on before replacing bolts with new ones. I used blue loctite, but many people suggest red for flywheels.
30. Scuff new clutch cover/pressure plate with 180 grit disc sander and clean to remove oil. Place clutch disc in position on flywheel, use alignment tool to center disc. Leave tool in place. Tool comes with LUK RepKit. (link)
31. Place new clutch cover on flywheel, it will NOT sit flush with flywheel, you need to repeat the removal process in reverse by installing cover bolts and hand tightening each evenly, then wrench them each 1 to ½ turns at a time until cover seats to flywheel. You’ll notice the fingers slowly begin to retract. (link)
32. Remove alignment tool.
33. Lubricate transmission input splines with provided spline grease sparingly; I used a brush to evenly distribute lubricant.
Stay Tuned for: Slave Cylinder...
Last edited by aallman72; Jun 4, 2012 at 10:27 PM.