Volkswagen Air Cooled 1949-1969 Repair Guide

Driven Disc and Pressure Plate

Print

REMOVAL & INSTALLATION





Click image to see an enlarged view

Fig. Fig. 1 The bent end of the clutch release bearing retaining clips shown as (a) in this diagram



Click image to see an enlarged view

Fig. Fig. 2 Use a small prytool to remove the clutch bearing retaining springs-be careful, because the springs are under tension

Manual Transaxle

  1. Remove the engine.
  2.  
  3. Remove the pressure plate securing bolts one turn at a time until all spring pressure is released.
  4.  
  5. Remove the bolts and remove the clutch assembly.
  6.  

Notice which side of the clutch disc faces the flywheel and install the new disc in the same direction.

  1. Before installing the new clutch, check the condition of the flywheel. It should not have excessive heat cracks and the friction surface should not be scored or warped. Check the condition of the throwout bearing. If the bearing is worn, replace it.
  2.  
  3. Lubricate the pilot bearing in the end of the crankshaft with grease.
  4.  
  5. Insert a pilot shaft, used for centering the clutch disc, through the clutch disc and place the disc against the flywheel. The pilot shaft will hold the disc in place.
  6.  
  7. Place the pressure plate over the disc and loosely install the bolts.
  8.  

Make sure the correct side of the clutch disc is facing outward. The disc will rub the flywheel if it is incorrectly positioned.

  1. After making sure that the pressure plate aligning dowels will fit into the pressure plate, gradually tighten the bolts.
  2.  
  3. Remove the pilot shaft and reinstall the engine.
  4.  
  5. Adjust the clutch pedal free-play.
  6.  

Automatic Stick-Shift
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine.
  4.  
  5. Remove the transaxle.
  6.  
  7. Remove the torque converter by sliding it off of the input shaft. Seal off the hub opening.
  8.  
  9. Mount the transaxle in a repair stand or on a suitable bench.
  10.  
  11. Loosen the clamp screw and pull off the clutch operating lever. Remove the transaxle cover.
  12.  
  13. Remove the hex nuts between the clutch housing and the transaxle case.
  14.  

Two nuts are located inside the differential housing.

  1. The oil need not be drained if the clutch is removed with the cover opening up and the gearshift housing breather blocked.
  2.  
  3. Pull the transaxle from the clutch housing studs.
  4.  
  5. Turn the clutch lever shaft to disengage the release bearing.
  6.  
  7. Remove both lower engine mounting bolts.
  8.  
  9. Loosen the clutch retaining bolts gradually and alternately to prevent distortion. Remove the bolts, pressure plate, clutch plate, and release bearing.
  10.  
  11. Do not wash the release bearing. Wipe it dry only.
  12.  
  13. Check the clutch plate, pressure plate, and release bearing for wear and damage. Check the clutch carrier plate, needle bearing, and seat for wear. Replace the necessary parts.
  14.  
  15. If the clutch is wet with ATF, replace the clutch carrier plate seal and the clutch disc. If the clutch is wet with transmission oil, replace the transaxle case seal and clutch disc.
  16.  
  17. Coat the release bearing guide on the transaxle case neck and both lugs on the release bearing with grease. Insert the bearing into the clutch.
  18.  
  19. Grease the carrier plate needle bearing. Install the clutch disc and pressure plate using a pilot shaft to center the disc on the flywheel.
  20.  
  21. Tighten the pressure plate retaining bolts evenly and alternately. Make sure that the release bearing is correctly located in the diaphragm spring.
  22.  
  23. Insert the lower engine mounting bolts from the front. Replace the sealing rings if necessary. Some units have aluminum sealing rings and cap nuts.
  24.  
  25. Push the transaxle onto the converter housing studs. Insert the clutch lever shaft behind the release bearing lugs. Push the release bearing onto the transaxle case neck. Tighten the bolts which hold the clutch housing to the transaxle case.
  26.  
  27. Install the clutch operating lever.
  28.  
  29. It is necessary to adjust the basic clutch setting. The clutch operating lever should contact the clutch housing. Tighten the lever clamp screw slightly.
  30.  
  31. First adjust dimension (a) to 0.335 in. Adjust dimension (b) to 3.03 in. Finally adjust dimension (c) to 1.6 in. by repositioning the clutch lever on the clutch shaft. Tighten the lever clamp screw.
  32.  
  33. Push the torque converter onto the support tube. Insert it into the turbine shaft by turning the converter.
  34.  
  35. Check the clutch play after installing the transaxle and engine.
  36.  

 
label.common.footer.alt.autozoneLogo