Volkswagen Air Cooled 1949-1969 Repair Guide

Clutch Cable

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ADJUSTMENT



Manual Transaxle


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Fig. Fig. 1 Clutch free-play should be measured at the pedal-pump the pedal several times before checking distance (a)



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Fig. Fig. 2 To adjust the clutch cable, turn the wing nut on the end of the cable-there should be approximately 2mm clearance between the clutch lever and the wing nut



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Fig. Fig. 3 For smooth clutch action, dimension (B) should equal 1.0-1.7 in.-to adjust the cable to provide the proper amount of sag at (B), install or remove washers from point (A)

  1. Check the clutch pedal travel by measuring the distance the pedal travels toward the floor until pressure is exerted against the clutch. The distance is 3 / 8 to 3 / 4 in.
  2.  
  3. To adjust the clutch, jack up the rear of the car and support it on jackstands.
  4.  
  5. Remove the left rear wheel.
  6.  
  7. Adjust the cable tension by turning the wing nut on the end of the clutch cable. Turning the wingnut counterclockwise decreases pedal free-play, turning it clockwise increases free-play.
  8.  
  9. When the adjustment is completed, the wings of the wingnut must be horizontal so that the lugs on the nut engage the recesses in the clutch lever.
  10.  
  11. Push on the clutch pedal several times and check the pedal free-play.
  12.  
  13. Install the wheel and lower the car.
  14.  

Automatic Stick-Shift

The adjustment is made on the linkage between the clutch arm and the vacuum servo unit. To check the clutch play:

  1. Disconnect the servo vacuum hose.
  2.  
  3. Measure the clearance between the upper edge of the servo unit mounting bracket and the lower edge of the adjusting turnbuckle. If the clearance (e) is 0.16 in. or more, the clutch needs adjustment.
  4.  
  5. Reconnect the vacuum hose.
  6.  

To adjust the clutch:
  1. Disconnect the servo vacuum hose.
  2.  
  3. Loosen the turnbuckle locknut and back it off completely to the lever arm. Then turn the servo turnbuckle against the locknut. Now back off the turnbuckle 5-5 1 / 2 turns. The distance between the locknut and the turnbuckle should be 0.25 in.
  4.  
  5. Tighten the locknut against the adjusting sleeve.
  6.  
  7. Reconnect the vacuum hose and road test the vehicle. The clutch is properly adjusted when Reverse gear can be engaged silently and the clutch does not slip on acceleration. If the clutch arm contacts the clutch housing, there is no more adjustment possible and the clutch plate must be replaced.
  8.  

The speed of engagement of the Automatic Stick Shift clutch is regulated by the vacuum operated valve, rather than by the driver's foot. The adjusting screw is on top of the valve under a small protective cap. Adjust the valve as follows:

  1. Remove the cap.
  2.  
  3. To slow the engagement, turn the adjusting screw 1 / 4 - 1 / 2 turn clockwise. To speed engagement, turn the screw counterclockwise.
  4.  
  5. Replace the cap.
  6.  
  7. Test operation by shifting from second gear to first gear at 44 mph without depressing the accelerator. The shift should take exactly one second to occur.
  8.  

REPLACEMENT



  1. Jack up the car and remove the left rear wheel.
  2.  
  3. Disconnect the cable from the clutch operating lever.
  4.  
  5. Remove the rubber boot from the end of the guide tube and off the end of the cable.
  6.  
  7. On Type 1, unbolt the pedal cluster and remove it from the car. It will also be necessary to disconnect the brake master cylinder pushrod and throttle cable from the pedal cluster. On Type 2, remove the cover under the pedal cluster, then remove the pin from the clevis on the end of the clutch cable. On Type 3, remove the frame head cover and remove the pin from the clevis on the end of the clutch cable.
  8.  
  9. Pull the cable out of its guide tube from the pedal cluster end.
  10.  
  11. Installation is the reverse of the removal procedure.
  12.  

Grease the cable before installing it and readjust the clutch pedal free-play.

 
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