Our High-Mileage Mk4 Gti Gets A Clutch And Flywheel Replacement From Act.
We've had the luxury of using the stock clutch in Project Silverstone for over 115000 miles! Amazingly, it's held strong even with software, exhaust, downpipe, intake, turbo inlet pipe, pulleys and more. Whoever was driving it must be a genius! (or a pussy - Ed)
But with plans for a bigger turbo, increased city driving and track use, the decision was made to replace the old clutch and flywheel. So we contacted Advanced Clutch Technology (ACT) in Lancaster, CA to see what options they had for the 02A transmission.
A common upgrade for 1.8T owners is dipping into the OE parts bin and sourcing a larger clutch and lighter flywheel from a VR6. We opted for ACT's Street kit intended for the VR6. Unlike other manufacturers, ACT rates its products based on torque capacity instead of stages. Their Street kit can handle 340 lb-ft of torque, measured at the flywheel. This should be plenty, considering our GTI's last dyno run produced 233 lb-ft at the wheels.
Open the box to their clutch kit and there's a heavy-duty pressure plate with 30% stronger clamp load over stock. A modified organic disc is also included, providing quicker engagement. Finally, a release bearing and alignment tool are incorporated, so you don't have to make a trip to the parts store for last-minute items.
Although not required in a clutch replacement, we also grabbed one of ACT's lightweight flywheels. It's a forged one-piece chromoly steel flywheel, weighing only 8.3 lb. Compared to the stock 22 lb part, this reduction should result in quicker throttle response.
For longevity, ACT's flywheels can be resurfaced for longer use, unlike aluminum flywheels.
The clutch and the flywheel we selected will fit any Mk4 VR6 or 1.8T five-speed, as well as other front-wheel drive applications like the Audi TT or Mk3 VR6 and Corrado.
If you're looking for a high performance clutch, ACT can also sell you a four- or six-puck pressure plate, sprung or unsprung. These stronger discs can be bought separately so you don't have to buy a new kit later when you upgrade. The parts should allow the transmission to handle 450 lb-ft of torque.
Impressions
We had the clutch fitted at EuroCode Tuning and as I reversed out of their garage and started my journey home, an enormous difference could be sensed in pedal feel, throttle response and acceleration. ACT recommends breaking the clutch in for the first couple of tanks of gas, but it was really hard to restrain myself.
At first, the clutch pedal felt heavier and more sensitive. I noticed the release point was higher than usual, causing me to stall it a few times. Soon after, I got used to the new feel and could tell the pedal was more responsive.
Shifting into each gear, the clutch gripped faster and the car wanted to engage more rapidly. Acceleration and throttle response were quicker, especially in first and second gear.
Rev-matching was also immediate. I can simply blip the throttle now, whereas the stock clutch required a longer push on the throttle.
A common pitfall of lightened flywheels is chatter and uneven idling, but I was relieved to notice the ACT kit didn't seem to have any of these problems.
After my second tank of gas, I'm now comfortable with the new clutch and can drive daily without any problems.
Installation
After winning the eurotuner GP challenge (et 1/08) in their 651whp Audi S4, we didn't hesitate to entrust our GTI to EuroCode Tuning located in Torrance, CA for the moderately difficult install. The job took their experienced mechanic four hours at a relaxed pace. It's best to have two people present, as you'll need to drop the transmission in order to access the clutch and flywheel. The process took around 40 steps, excluding reassembly, but we've condensed it to provide you with a helpful guide.