Overview
A detailed step-by-step process for diagnosing and replacing the clutch assembly on a Volkswagen Golf Mk6 (2010, 1.4L), identifying a faulty thrust bearing and fork as the source of a sticky clutch pedal, and confirming successful repair after reassembly and road testing.
Diagnosis and Preparation
- Customer reported intermittent sticky clutch pedal.
- Initial checks failed to reproduce the issue until clutch stuck once, confirming problem within the clutch assembly.
- Decided to replace clutch kit after identifying internal clutch problem.
- Vehicle raised and right/left wheels removed for access.
- Wheel arch panels, airbox, and battery removed to clear space for gearbox removal.
- Battery voltage maintained via OBD2-connected power supply during removal.
Disassembly Process
- Airbox, battery, and battery tray removed for upper access.
- Gear linkage cables disconnected and slave cylinder accessed.
- Starter motor unbolted and secured out of the way.
- CV shafts and lower suspension components disconnected for gearbox clearance.
- Sway bar link removed and CV shafts tied up for additional room.
- Engine supported with jack as gearbox mounts disconnected.
- Gearbox bolts, particularly those obstructed by chassis/exhaust, carefully removed.
- Gearbox slid back on a bike stand, not completely extracted, just far enough to service clutch.
Fault Identification
- Thrust bearing and sleeve showed significant wear, rust, and groove marks, likely causing clutch pedal to stick.
- Clutch plate and pressure plate exhibited dryness and minor burn marks, but no catastrophic wear.
- Clutch fork and yoke displayed uneven wear and scraping, corroborating sticking issue.
- Confirmed gearbox model (MQ2 200) for correct parts selection.
New Clutch Assembly & Installation Tips
- Clutch kit (Clutch Pro KVW 22016) included new clutch plate, pressure plate, thrust bearing, and fork.
- Flywheel cleaned and abraded; no seal leaks noted.
- Emphasized cleanliness and lubrication at contact and pivot points during reassembly.
- Pressure plate aligned using old plate for easier fitment; torque specs followed.
- New thrust bearing assembled onto fork with correct orientation and lubrication.
- Gearbox maneuvered back into position with careful tilting and alignment, aided by jacks and makeshift supports.
Reassembly and Testing
- Gearbox, mounts, starter motor, and earth strap reinstalled.
- Gear linkages, half shafts, and sway bar reconnected; bolts torqued to spec.
- Battery tray, battery, and airbox replaced; power supply ensured no ECU resets.
- Clutch function tested on quick jacks prior to full road test; clutch pedal operation confirmed smooth.
- Vehicle road tested, confirming sticky clutch issue resolved and pedal feel improved.
Decisions
- Replace entire clutch kit and thrust bearing/fork assembly.
- Clean and reuse flywheel as no major wear or leaking observed.
Action Items
- TBD – Miracle Max: Road test vehicle further and confirm customer satisfaction.
Recommendations / Advice
- Always check for proper lubrication and wear on thrust bearing and fork when diagnosing sticky clutch.
- Verify gearbox model before ordering replacement parts.
- Use an auxiliary power supply when disconnecting battery to preserve vehicle settings.