Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION




CAUTION
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.

Except Dasher, Fox and Quantum

See Figures 1, 2, 3, 4, 5 and 6

You'll need special tool VW 547, VW 3190 or similar clutch pilot tool to center the clutch disc.

These cars use a type of clutch more common to motorcycles than to cars. The pressure plate is bolted to the crankshaft and the flywheel is bolted to the pressure plate; in other words, these two parts have switched places. The clutch release lever and bearing are in the left end of the transaxle. The clutch is actuated by a release rod which passes through a hollow transaxle shaft. The throwout bearing is in the transaxle and is lubricated with transaxle oil.



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Fig. Fig. 1: Rabbit, Golf, Jetta and Scirocco clutch assembly



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Fig. Fig. 2: Attach a flywheel locking tool to prevent the flywheel from turning

  1. Remove the transaxle, as described earlier in this section.
  2.  
  3. Attach a toothed flywheel locking device and gradually loosen the flywheel to pressure plate bolts one or two turns at a time in a crisscross pattern to prevent distortion.
  4.  
  5. Remove the flywheel and the clutch disc.
  6.  
  7. If replacing the flywheel, some new ones haves only a TDC mark. Additional timing marks must be cut into the flywheel. Refer to the illustration. Dimension "A" is 5 / 8 in. (16mm) and "B" is 3 / 32 in. (2.5mm). Timing mark "A" is 7 1 / 2 degrees BTDC and "B" is 3 degrees ATDC.
  8.  
  9. Use a small prybar to remove the release plate retaining ring. Remove the release plate.
  10.  



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Fig. Fig. 3: Remove the flywheel and clutch disc after removing the retaining bolts



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Fig. Fig. 4: Some new flywheels must have an additional timing mark cut into them



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Fig. Fig. 5: Use a small prybar to remove the retaining ring

  1. Lock the pressure plate in place and unbolt it from the crankshaft. Loosen the bolts one or two turns at a time in a crisscross pattern to prevent distortion.
  2.  

To install:
  1. Use new bolts to attach the pressure plate to the crankshaft, and be sure to use a thread locking compound. Torque the bolts in a diagonal pattern to 54 ft. lbs. (73 Nm) on pre-1985 models, or 74 ft. lbs. (100 Nm) on 1985 and later models.
  2.  
  3. Lubricate the clutch disc splines, release plate contact surface, and pushrod socket with multi-purpose grease. Install the release plate, retaining ring, and clutch disc.
  4.  
  5. Use special tool VW 547 or equivalent clutch pilot tool to center the clutch disc.
  6.  
  7. Install the flywheel, tightening the bolts one or two turns at a time in a crisscross pattern to prevent distortion. Torque the bolts to 14 ft. lbs. (20 Nm).
  8.  
  9. Install the transaxle, as described earlier in this section. Adjust the clutch free-play.
  10.  

Dasher, Fox and Quantum
  1. Remove the transaxle, as described earlier in this section.
  2.  
  3. Matchmark the flywheel and pressure plate if the pressure plate is being reused.
  4.  
  5. Gradually loosen the pressure plate bolts one or two turns at a time in a crisscross pattern to prevent distortion.
  6.  
  7. Remove the pressure plate and disc.
  8.  
  9. Check the clutch disc for uneven or excessive lining wear. The rivets in the plate should be tight and indented in the mating surface, not level with it.
  10.  
  11. Examine the pressure plate for cracking, scorching, or scoring. Replace any questionable components.
  12.  

To install:
  1. Install the clutch disc and pressure plate. Use a pilot shaft (available at most auto parts stores) or an old transaxle shaft to keep the disc centered.
  2.  

The use of the proper pilot shaft is a necessity; if you can't obtain one, don't use "dead reckoning" to line up the clutch. You'll spend a long, sweaty time trying to force the transaxle spline into the misaligned clutch.

  1. Gradually tighten the pressure plate-to-flywheel bolts in a crisscross pattern. Tighten the bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the throwout bearing, if removed.
  4.  
  5. Apply a light film of grease to the input spline on the transaxle to aid in inserting it into the clutch. Don't go overboard with the amount of grease.
  6.  
  7. Install the transaxle, as described earlier in this section.
  8.  



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Fig. Fig. 6: Flywheel tightening sequence

 
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