Volkswagen Air-Cooled 1970-1981 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



Manual Transaxle

See Figures 1 and 2

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the clutch assembly (driven disc, pressure plate and related components) used in Type 4 models-note that the clutch face (F) is normally attached to the clutch plate (E)



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Fig. Fig. 2: Cutaway view of the clutch release bearing and guide sleeve-the guide sleeve helps with the release bearing engagement

  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 See Figures 3 and 4

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Fig. Fig. 3: Adjust the automatic stick shift clutch to the 3 dimensions shown (a, b and c)-a should equal 0.335 in., b should equal 3.03 in. and c should be adjusted to 1.6 in.



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Fig. Fig. 4: When checking the clutch adjustment on automatic stick shift transaxles, e should be less than 0.16 in.

  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.  

CLUTCH CABLE ADJUSTMENT



Manual Transaxle
  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.  

CLUTCH CABLE REPLACEMENT Types 1, 2, and 3



See Figure 5

Click image to see an enlarged view

Fig. Fig. 5: For smooth clutch action on Type 1 models, 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. 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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