UrS4boy

There isn't a clutch DIY in the UrScar FAQ so far. If there was, in general, I think it would go something like this:

Purchase a clutch kit. Up to RS2 plus levels the stock Luk should be fine. Clutch kit should include the pressure plate, non-sprung clutch disk, throw-out bearing and clutch alignment tool. You will need to buy the needle bearing that sits in the flywheel and holds the end of the transmission input shaft, PN 034 105 313A. You might also want to consider replacing the rear crank seal, PN 068 103 171 F.

Once you have the parts, the R&R procedure is as follows:

1. Drop exhaust system from the cat inlets to tailpipe (as one unit). Be prepared to cut bolts at cats. (If you do, the bolts are N 010 353 3, the nuts are N 900 850 01, you need six of each).
2. Disconnect drive shaft at end of transmission. Tie out of the way. (If that doesn't work, the whole drive shaft will have to come down, including the center bearing).
3. Disconnect clutch slave cylinder.
4. Disconnect reverse switch
5. Disconnect shift mechanism from tranny.
6. Disconnect ProConTen (Not needed on 95.5 S6)
7. Disconnect and remove starter
8. Remove all transmission bolts (be prepared for the odd 14 mm and 16 mm bolt, IIRC)
9. Slide transmission out and drop (using tranny stand).
10. Remove clutch (the easiest part).
11. Consider resurfacing flywheel if you see hot spots (remove as required)
12. Remove transmission input shaft needle bearing from flywheel.
13. Consider doing the rear seal (only 8 bolts hold on the flywheel - easy with an impact wrench).
14. Install new needle bearing and begin reinstalling, using clutch alignment tool to line up clutch.
15. Installation is reverse of removal. (Ha).

tpierce

also, it's easier to refill the transmission if you want to drain and refill it at that time. also, greasing up joints on the driveshaft at this time would be much easier than normal. Do our cars have a grease zerk on the driveshaft? I know my cq did, the only way you can get to it is with the exhaust out of the way.

mchaloux

disconnect battery before disconnecting electrical components

VR_Life

You mean the cork gaskets on the shaft ? That is a must replace unless you like throwing CV grease