Homemade tools.
 

While doing a clutch change on my '89 200 tqa, I decided to clean up the transmission and replace all seals and shifter bushings. Here are a few tools I came up with to insert seals etc. Tomorrow - Homemade Crank holding tool to remove flywheel & future timing belt change.

1 1/4" OD X 6" Aluminum pipe(Mainshaft input seal), Delrin insert tools(Front axle seals, Pilot bearing)
<img src="http://pictureposter.audiworld.com/51307/10-04-04a.jpg">

Mainshaft input seal
<img src="http://pictureposter.audiworld.com/51307/10-04-04b.jpg">

Ready to go in
<img src="http://pictureposter.audiworld.com/51307/10-04-04c.jpg">

In
<img src="http://pictureposter.audiworld.com/51307/10-04-04d.jpg">

Front axle seal
<img src="http://pictureposter.audiworld.com/51307/10-04-04e.jpg">

In (gonna do the 3 holed selector shaft cover gasket next)
<img src="http://pictureposter.audiworld.com/51307/10-04-04f.jpg">

Other side in (hard to see new bushings in shift levers and the new Speedo sensor to replace the one I broke :)
<img src="http://pictureposter.audiworld.com/51307/10-04-04g.jpg">

Re: Homemade tools.
 

How was the clutch change process? how long did it take you? Any advice for someone thinking about doing one in the near future?

LOL, how long? still not done
 

I'm a single father of 3 children(18,12,10). Between baseball, football, volleyball &amp; work, I've been taking my time with this project.
1st I degreased the entire transmission
2nd I touched up painted parts
And now finally getting around to putting it all back together before winter flies. All in all it isn't that bad. A transmission jack is nice if doing it by yourself.

Re: LOL, how long? still not done
 

You're more thorough than I would be. I'm talking drop the trans, slap a new clutch on, call it a weekend. :)

Should be doable, that was my first thought too. PARTS LIST
 

I had a T/O bearing go bad on me, hence the clutch job. But once I had the transmission out I figured I'd go for it. The right axle seal was leaking so it was quite a mess to begin with. After degreasing &amp; paint I decided to replace everything. Still need to get flywheel surfaced.
1. Sachs clutch kit
2. Clutch slave cylinder
3. T/O guide sleeve
4. Pilot bearing
5. Mainshaft input seal
6. Front axle seals
7. Selector shaft cover gasket
8. Driveshaft center support bearing
9. Transmission mounts
10. Crankshaft seal kit
11. Shift rod bushings (set of 2)
12. Flywheel Bolts

I wanna see the crank tool for sure.

Re: Homemade tools.
 

I made a crank tool as well, used a large plumbing fitting with a large nut end and thread end. Ground down the thread end to fit in the pulley and cut a notch in it.

So to use it, I put a large plumbers wrench and pipe on the wrench and a breaker bar with a pipe on the nut. Takes two men one holds the pulley the other turns the nut...it works well.

Boy that bolt is tight

R

here is mine, the top one, the second to the top is my cam gear holder
 

<center><img src="http://pictureposter.audiworld.com/50623/hankstools_003.jpg"></center><p>The bottom two are for pluckin valves out

Ya, something like that ........

Nice setup, I have some factory tools...
 

Factory crank lock tools and oil seal puller thingy. I have the injector puller tool and I think a few other misc things.
Nice job on those, they look good!

Mike