Volkswagen Workshop Service and Repair Manuals

Note:

When repairs are required to the clutch, the gearbox must be removed =>page 34-17

TDC sensor adapter in clutch housing=>page 34-76

When removing and installing the clutch in addition to the notes in the Workshop manual the following should be noted:

Clean input shaft splines and with used clutch plates clean hub splines, remove corrosion and apply a very thin coat of G 000 100 grease to the input shaft, until the hub move freely on the shaft. Remove surplus grease without fail.

• 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 M10 x 1 x 20
• ◆ Renew, Installed with D6 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 7 x 40, 20Nm
• Clutch push rod
• ◆ Grease at bush location 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 (200mm 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

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