Clutch kit Luk or Exedy
Last month, I replaced the clutch kit and DMF on my 1999 PD115 Passat with a LuK kit, and it was also slipping in 4th and 5th when I floored it (stock tune). After about a week of casual driving, it bedded in, and I had no problems since.
The clutch kit, buy the luk kit pn 07233 on rock auto. It's $500 and change with shipping. Plan a couple of days on the weekend to r&r the transmission.
Exedy = OEM, I'd take that over ANY other manufacturers for the platform other than Nismo.
I've been rocking the Exedy kit for about a year now, very happy with it. It's responsive enough where I can have fun, still light but with no chatter. I've driven a 2 stage clutch Z33 before and it was way too heavy for for DD imo. Can't speak on Z1, but I love exedy.
I ordered the exedy OE clutch kit from ftspeed. About to have it installed next week. And although it doesn't have the white paint dot on it, I seen a comparison between the new and old and it looks like the new. The two tabs don't have the cutout in it like the old one does
Retail on OES (Luk) -not cheap-o part) clutch kit is $400 (RETAIL) comes w slave cyl as well. Master cyl is about $100 retail.
I did an Exedy Stage 1, slightly stiffer than stock but a nice feel to it for something you drive regularly
I know a lot of folks swear by Exedy, however the one and only Exedy clutch I have ever used is in my 06 and it shudders like crazy. I like LUK and have used a dozen times without issue.
Buy oem. Go on any rotary vender (atkins, mazdatrix) and order oem exedy #1007 I think . I tried saving money ordered from ebay but pilot and release/ throwout bearing was wrong and cost me more in long run. Exedy stage 1 has throwout bearing issues apparently. If you want a slight upgrade, buy the oem exedy s2 rx8 clutch kit.
I replaced the disc with LUKs kit and also had my flywheel resurfaced to be safe. The new set-up has about 300 miles on it and continues to slip. Most noticeably around 2700 - 3400 rpm in 3rd and 4th gear. I can feel it seem to slip then catch and gain a magical 15 hp. I have not allowed the clutch to slip enough to have glazed the clutch disc so that's not a possibility, and my "auto" adjusting clutch cable seems to be okay (I can push the transmission arm downwards and the clutch cable spring returns it to the 9 o'clock position). Proper torque specs and sequence were followed and everything was extremely clean upon installation. Also there are no leaks so there is no fluid getting on the disc. New clutch disc, re-surfaced flywheel, new rear main seal, new pressure plate.
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