9n ATD Polo 1.9 TDi - Clutch

[Bospatrollie]

Morning All,

My car's clutch is on it's last legs. First the thrust bearing started complaining and last week I started hearing a humming when in 5th at about 120 km/h when I apply torque, i.e press the accelerator. Next thing, this morning, coming off of the highway into an off ramp, I had to shift down as I am decelerating ... and I had almost no clutch. I checked the slave and it's dry, so I suspect it is time now.

Problem is ... I cannot afford the average R8K to replace the whole DMF kit (that is not even VW pricing!). I know there are SMF alternatives, but I don't know if that would be the best option to follow. Also, when phoning around and asking for prices, I am lead to the conclusion that VW, for some reason, produced some of the 9n TDis with SACHS clutches ... and others with a LuK ... everywhere I get asked which clutch? What gives?

This couldn't have happened at a worst time, to be honest. Well, strictly spoken, stuff can almost always happen at a worst time, but amongst toe worst of the worst times, this time is right up there!

[Bospatrollie]

A friend of mine has a 6-speed box he is willing to let go to me for R 3'500. Will that box fit on my polo without hassle? I don't know if the crank and flywheel will match ... never opened one of these before.

[Pynoxim]

A friend of mine has a 6-speed box he is willing to let go to me for R 3'500. Will that box fit on my polo without hassle? I don't know if the crank and flywheel will match ... never opened one of these before.

6 Speed = 240mm Flywheel
5 Speed = 228mm Flywheel

You'll need a different clutch kit

[Neuk]

A friend of mine has a 6-speed box he is willing to let go to me for R 3'500. Will that box fit on my polo without hassle? I don't know if the crank and flywheel will match ... never opened one of these before.

6 Speed = 240mm Flywheel
5 Speed = 228mm Flywheel

You'll need a different clutch kit

And the CV's are different, driveshafts are different, brakes are different, etc, etc.

[Bospatrollie]

A friend of mine has a 6-speed box he is willing to let go to me for R 3'500. Will that box fit on my polo without hassle? I don't know if the crank and flywheel will match ... never opened one of these before.

6 Speed = 240mm Flywheel
5 Speed = 228mm Flywheel

You'll need a different clutch kit

And the CV's are different, driveshafts are different, brakes are different, etc, etc.

Okay, bin that idea then. Suppose I'll just have to do the clutch and then try and see why it started whining in 5th when I apply torque ... switching over to 6-speed is going to be more expensive than I can justify at the moment.

Thanks for the feed back.

[Bospatrollie]

A friend of mine has a 6-speed box he is willing to let go to me for R 3'500. Will that box fit on my polo without hassle? I don't know if the crank and flywheel will match ... never opened one of these before.

6 Speed = 240mm Flywheel
5 Speed = 228mm Flywheel

You'll need a different clutch kit

Dammit ... well thank you for letting me know before I jumped in head-over-heels and sat with a bag of baked potatoes ...

[Bospatrollie]

Is the SMF a sensible option? I don't tow much ... maybe 3 times a year and only Venter trailer ... except if I help a family member move. It is quite a bit more affordable than the DMF. I know the DMF is smoother, I just don't know by how much.

[panic-mechanic]

make sure the gearox oil elevel is right. Why would towing be an issue with SMF. Literally all that is different is that it is a little less smooth. Not less capable or anything like that.

[GremlinCCS]

Fyi. Done the gearbox swop to 6 speed.

Flywheel and clutch kit are a must. I found the clutch kit for around, R6k from goldwagen
Got the flywheel and box for 5k
Gearbox mounting are different, same mounting as the DSG.
Sourced the mounting point on the gearbox at a scrap yard as no one sells them.
Left driveshaft are same size as original, right are a bit shorter. Found one at a scrap yard after searching around 20 of them. Agents cost are over 11k as they only sell them with both cv's. Got it for 1500.
Shifter cable mounting are different. Couldn't get one so we modded the one of the 5speed.

Are it worth it? Well I had to, to fit the new motor but with the previous 1.9tdi motor as I load the caddy a lot I had a lot of wheel spin taking off up hill. Now non as I believe the 6 speed have a LSD.

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[Bospatrollie]

So I ended up closing my eyes, selling my other car to fix the TDi by rplacing a full DMF and clutch kit. Now I will have to replace/recon the 'box at some stage, as I can clearly hear the gear-rollover and she is starting to whine in 4th and 5th. Thanks for all the advice so far All.

[werd]

get a SMF kit from GW, you wont notice any difference other than the price.

and they about 40% stronger in any case.
and WAY cheaper next time you cnhange clutch as you will only need to replace clutch and not flywheel.

working like a charm on my car!

[Bospatrollie]

Hi All ... any suggestions on where I might find recon kits for the 'box? The whine in 4th and 5th is getting worse and I am not sure if it is the pilot bearing or the bearing set between 4th and 5th? Goldwagen Pta North said that I can get the pilot bearing only at VW and VW Hatfield said the price is R4'200 excl VAT!!!

I am sure that somewhere, someone knows something that'll make this a more affordable exercise ...

[GremlinCCS]

I paid 5k for my 6speed box. So bearing kit at 4 200 sounds very high.

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[panic-mechanic]

Try erlemans in jhb.

[Bospatrollie]

Try erlemans in jhb.

Thanks Panic ... appropriately ... I AM in a PANIC!