The New Addition- MKIV GLI

[Slamtastic]

Re: The New Addition- MKIV GLI

Hmmm... I wonder how much clutch wear I caused and how much the idiot before me caused... haha

Hopefully nothing too major

Here's a video of the culprit of this rebuild. The Input Shaft bearing. There are 2 along the shaft, one in the casing and this one at the end. There is a poor lubrication design which causes the bearing to overheat and fail.



Pulling bearing off.


Off. Notice a bit of the plastic holding the balls in has deformed from overheating.



Cooling the shaft to shrink it a bit.



Heating up new bearing to expand it.



New Bearing dropped right on, new circlip installed.



Other input bearing removed.


I will have to wait for some more parts before finishing up that. Time to get started on the Shift forks. They are held together with a rivet that is known to shear off causing gears to be lost.

First I drilled the rivet out and scuffed up the joining parts.



Put a dab of JB weld between the 2 parts and left clamped overnight.



Tapped with a M8x1.25 bit.



Threaded in a M8x1.25x30 Grade 12.9 Bolt with a bit of red loctite.



Cut off the majority of the end.



Ground down the rest. I will be tack welding the end of the bolt to ensure it doesn't come out.



Then repeated with the other fork.



I ordered the rest of my parts today and will be going down to the states next weekend to pick them up. I will hopefully be able to get the transmission done and back in by Christmas if all goes well.

Stay tuned!

[Slamtastic]

Re: The New Addition- MKIV GLI

Here's the rest of the progress from finishing up the transmission.

Shift Fork bolts welded.


Diff bearings replaced along with races. All other journal and races were fine, so I left them. I pondered the idea of an LSD, but with no plans of making big power and the fact that I no longer drive it in winter made me not want to spend $900 right now. Maybe next winter.


Second input shaft bearing replaced.



Shafts, forks and diff back in place. Everything needs to go in at the same time in a certain order. Huge PITA.


New Clutch & throwout bearing/Slave Cylinder Installed. I messed up and neglected to bench bleed the slave before putting the tranny back in. This resulted in 5 hours of clutch bleeding (without a power bleeder). Definitely should've done a bit more research before that step. :(



Sealant on casing. Kinda went overboard but I wanted to make sure it won't leak. Also, I made the mistake of buying OEM sealant for $120/100mL tube. Permatex makes a grey import sealant that is the exact same for around $10. At least I know the OEM stuff works.


All buttoned up, so clean and shiny


I still haven't gotten a chance to drive it as I started on the rear refresh, but it moved up and down the driveway fine, so hopefully I'm in the clear. Hopefully this mini 'build' can help someone in the future.

Also, thank to Sean for the extra set of hands with getting the trans in and out.

Here's a list of everything that was done with a few more pics:
-Ball Joints
-Tie Rod Assemblies
-Control Arm Bushings (R32)
-Air Horn
-Valeo Clutch with single mass flywheel
-Diff bearings
-Input Shaft Bearings
-All Transmission Seals
-Polished Intake Manifold
-Gear Oil Change
-Notched subframe
-Painted subframe, rear beam, control arms, etc.
-Front Wheel Bearings
-Rear beam bushings
-Repaired carpet wear from PO beside gas pedal
-Outer Passenger CV boot replaced

[Slamtastic]

Re: The New Addition- MKIV GLI

Put the rear beam back in but I didn't like how the meyle bushings pressed in on install. Sure enough they caused the beam to be over 2mm on one side. Took the axle back out and replaced the bushings with poly ones from energy suspension. I know some people advise against it but I figured that I'd give them a shot. Went in much easier and the beam was even after. Also undercoated under the car (not shown).



Got to work on re-doing the trunk setup. Sound dampened the entire trunk, under rear seats, rear deck lid, and under trunk lid carpet.







All done. Just have to finish cleaning up the wiring and get a new leader line for the viair compressor.





Back on the road after 5.5 months! The sad thing is the transmission is still making the same whining noise it was before the rebuild which sucks, but I'll deal with that next winter.







And my favorite part. Sits under 1/4" from the ground laid out

[AllGo'n'Show]

Re: The New Addition- MKIV GLI

Wow, great work she looks awesome

[CGDoig]

Re: The New Addition- MKIV GLI

Props Ryan. Huge props. That tranny job isn't to be taken lightely. Looks like a millwright did it. I would love to do some of this stuff if I had a second car to drive too, love it.

[Slamtastic]

Re: The New Addition- MKIV GLI

Wow, great work she looks awesome

Thanks man! I'm happy how it came out!

Props Ryan. Huge props. That tranny job isn't to be taken lightely. Looks like a millwright did it. I would love to do some of this stuff if I had a second car to drive too, love it.

Appreciate it Cam! Kind of sucks that it is still making the same noise but it was a learning experience for sure! Shouldn't take as long next time.

[P Arkus]

Re: The New Addition- MKIV GLI

Looks stunning as always Ryan. Love your car!

[Geobmx4life]

Re: The New Addition- MKIV GLI

All of the above Ryan...well done!

[kujiwara]

Re: The New Addition- MKIV GLI

Simple and clean, nice! What's the last picture about?

[Slamtastic]

Re: The New Addition- MKIV GLI

Thanks guys

Simple and clean, nice! What's the last picture about?

It's a 160+ dB air horn

[Bucky]

Re: The New Addition- MKIV GLI

Great Looking car. Looking forward to seeing it this summer.

Keep up the good work.

[Danaldson]

Re: The New Addition- MKIV GLI

Simple and clean, nice! What's the last picture about?

lol simple? yeah right. Amazing work ryan!! I love how your car sits when aired out.

[Slamtastic]

Re: The New Addition- MKIV GLI

Appreciate the love guys Gonna try to make it to more shows this summer. Hoping the snow stays away in the mean time.