Volkswagen Workshop Service and Repair Manuals

Note:

Remove gearbox beforehand.

When removing and installing the clutch following should be noted:

Clean the splines on drive shaft and, with used clutch plate the splines in the hub, remove corrosion and apply a thin coat of grease G 000 100 to the drive shaft. Then move plate to and fro on the shaft until the hub moves freely on the shaft. Surplus grease must be removed.

TDC sensor adapter in clutch housing .

• Flywheel
• ◆ Removing and installing - Fig.1
• ◆ Ensure that centering pins are tight, contact surface for plate must be free of grooves, oil and grease.
• Clutch plate
• ◆ Centering - Fig. 2
• ◆ Checking for lateral run-out - Fig.3
• ◆ Coat splines lightly with Molykote or Molyspray.
• Retaining ring
• ◆ Lever out with screwdriver
  watch position - Fig.4
• Release plate
• ◆ Coat contact surface and socket for clutch push rod lightly with Lithium grease.
• Screw M 10x1x20
• ◆ Renew, Installed with D 6 locking fluid
• ◆ With shoulder 100 Nm
• ◆ Without shoulder 75 Nm
• Packing plate

• Pressure plate
• ◆ Removing and installing
• ◆ Checking - Fig.6, pressure plates with damaged or loose rivets should be renewed.
• Release plate
• ◆ For 200 mm dia. clutch coat surface and socket for clutch push rod lightly with Lithium grease.
• Retaining ring
• ◆ For 200 mm dia. clutch lever out with screwdriver, watch position Fig. 5
• Screw
• ◆ M 7x40
  20 Nm
• Clutch push rod
• ◆ Grease at bush locations in drive shaft.

Fig.1     Removing and installing flywheel

Fig.2     Installing clutch plate

• ‒ Tighten screws alternately and diagonally to 20 Nm

Fig.3     Removing and installing pressure plate

Note:

To fit the 200 mm clutch the retainer VW 558 must be reworked as shown in fig. 9.

Fig.4     Installing retaining ring (190 mm clutch)

Watch position of ring ends

Fig.5     Installing retaining ring (200 mm clutch)

Watch position of ring ends.

Fig.6     Checking pressure plate for distortion, cracks and signs of burning

Maximum inward taper 0.2 mm.

Fig.7     Check spring connections between pressure plate and cover for cracks, loose rivets and security

Clutches with damaged or loose rivets should be renewed.

Fig.8     Checking clutch plate for lateral run-out

Max. 0.3 mm (Measured 2.5 mm from outer edge)

Fig.9     Reworking retainer VW 558

The shaded area must be reworked to dimensions given.

Note:

The 200 dia. clutch can be service installed by replacing the pressure plate, flywheel , clutch plate, release plate and retaining ring.