Volkswagen Air-Cooled 1970-1981 Repair Guide

Understanding the Clutch


See Figures 1 and 2

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Fig. Fig. 1: Exploded view of the manual transaxle clutch system used on Types 1, 2 and 3

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Fig. Fig. 2: Hydraulic clutch system components used on Type 4 models

The clutch used in all models is a single dry disc mounted on the flywheel with a diaphragm spring type pressure plate. The release bearing is the ball bearing type and does not require lubrication. On Types 1, 2 (except Vanagon), and 3, the clutch is engaged mechanically via a cable which attaches to the clutch pedal. On the Type 4 and the Vanagon, the clutch is engaged hydraulically, using a clutch pedal operated master cylinder and a bell housing mounted slave cylinder.

The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

The purpose of the clutch is to disconnect and connect engine power at the transaxle. A vehicle at rest requires a lot of engine torque to get all that weight moving. An internal combustion engine does not develop a high starting torque (unlike steam engines) so it must be allowed to operate without any load until it builds up enough torque to move the vehicle. Torque increases with engine rpm. The clutch allows the engine to build up torque by physically disconnecting the engine from the transaxle, relieving the engine of any load or resistance.

The transfer of engine power to the transaxle (the load) must be smooth and gradual; if it weren't, drive line components would wear out or break quickly. This gradual power transfer is made possible by gradually releasing the clutch pedal. The clutch disc and pressure plate are the connecting link between the engine and transaxle. When the clutch pedal is released, the disc and plate contact each other (the clutch is engaged) physically joining the engine and transaxle. When the pedal is pushed inward, the disc and plate separate (the clutch is disengaged) disconnecting the engine from the transaxle.

Most clutches utilize a single plate, dry friction disc with a diaphragm-style spring pressure plate. The clutch disc has a splined hub which attaches the disc to the input shaft. The disc has friction material where it contacts the flywheel and pressure plate. Torsion springs on the disc help absorb engine torque pulses. The pressure plate applies pressure to the clutch disc, holding it tight against the surface of the flywheel. The clutch operating mechanism consists of a release bearing, fork and cylinder assembly.

The release fork and actuating linkage transfer pedal motion to the release bearing. In the engaged position (pedal released) the diaphragm spring holds the pressure plate against the clutch disc, so engine torque is transmitted to the input shaft. When the clutch pedal is depressed, the release bearing pushes the diaphragm spring center toward the flywheel. The diaphragm spring pivots the fulcrum, relieving the load on the pressure plate. Steel spring straps riveted to the clutch cover lift the pressure plate from the clutch disc, disengaging the engine drive from the transaxle and enabling the gears to be changed.

The clutch is operating properly if:

  1. It will stall the engine when released with the vehicle held stationary.
  3. The shift lever can be moved freely between 1st and reverse gears when the vehicle is stationary and the clutch disengaged.