UKPassats

Hey guys Thanks for checking out my thread. I need to replace the clutch (slipping) in my 2003 passat TDI (engine AWX gearbox FHN) and have noticed the gear shifter moving as I accelerate/decelerate (worst in second). I had a test drive with my local gearbox specialist and he said that it indicated ...

Thanks again Aidan sounds like a plan!

Heya Aidan, Great! I'll go ahead with that LUK clutch and DMF set, that eBay listing doesn't specify 5 speed but I've emailed the retailer who confirms that it'll fit the AWX / FHN combo... I'm definitely getting every seal for the gearbox while it's off, as well as a pilot bearing; and may as well ...

Hey guys, I've gotten time to do this job so need to start ordering the parts. My plan is to go to my local VW dealership to order the seals, I know other companies sell them but trying to figure out which seals to buy for this transmission (FHN) is proving difficult. I've been doing a little more r...

Fantastic! I'll order them now.

Mike

That's a great guide!

When you say "you need to carefully pick the old one out (i have seal picks, the range sell the for a couple of quid and they’re flaming brilliant)" which brand of pick set was that?

Cheers!
Mike

That's great thanks! I'll replace all of those bits. Once I have the box out of the car and all the parts have arrived I should be able to figure out how the seals come off and how the new ones go in.

I haven't looked yet but I'll scan this forum for your posts Aidan.

Cheers!
Mike

Thanks for the suggestions guys! The car has only 120k on it and I've replaced loads of gear so I'd defo like to persevere with it. The clutch feel has definitely got worse, so it'll have a new clutch once the box is off. The engine oil is just about due for a change so is pretty dark, all of the oi...

Hey guys, I finally got around to taking videos of the transmission to see if we can figure out where the leak is coming from: At the beginning of this video you can see oil forming on the left hand side of the video, you can then see it's also near the front of the transmission. https://photos.app....

Ok I'll take some photos when trying to locate the leak and will post them.

Cheers!
Mike

Ok thanks for that! If it is the clutch slave cylinder leaking would I be losing transmission oil or brake fluid? Lastly, is there a pigment (UV?) I can add tot he transmission oil in order to help discover where the leak is coming from>

Cheers
Mike

Ok that's helpful, at least I know it's not a stupid idea; as it wouldn't take long it may be worth a shot. I've been searching for the location of the clutch slave cylinder for the fhn tranny on the net but am not having any luck. Is it attached to the outside of the tranny? Is it best checked from...

Thanks for your reply MiniMental, I know it's leaking from the transmission as the transmission started to feel clunky so I checked and refilled the oil level; it was missing just over a litre. I paid a company who turned out to be poo to work on my transmission, they didn't make it any worse but di...

Thanks for looking at my thread. I think I have a transmission (FHN) gasket leak (2003 b5.5 passat TDI), is it worth an attempt to stop the leak using permatex rightstuff gasket maker? I'd just apply a bead to where the transmission is bolted to the engine and smooth it down. It's only a very slow l...

Thanks for your reply CTP! In my case the inner bush has gone on both arms and the ball joints attached to the arms are ok, but I'll take your word for it and will get the complete arm units.

Mike

Hey guys, Thanks for looking at my thread. Do the two bushings on each front lower suspension arm last substantially longer than the ball joint at the end of each arm? The reason I ask is that upgraded bushings are available for sale individually and the ball joint is not, my Haynes manual says the ...

Thanks for your reply 1.9 Tdi ! I managed to get to it by removing the air ducting and (after much swearing) have installed the new oil line. I dropped a couple of the 10mm bolts which belong to the P clips which have disappeared, I hope they didn't end up in the clutch vent holes! :/

Heya thanks for looking at my thread.

I'm replacing the turbo oil feed line and have removed it from the Turbo and undone the Banjo bolt, the line is attached to back of engine and I can't see / feel how to remove it, can any one help?

Cheers!
Mike