REMOVAL & INSTALLATION
The clutch driven disc contains 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.
This type of clutch is similar to a motorcycle clutch. The pressure plate is bolted to the crankshaft and the flywheel bolted to the pressure plate. 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 throw-out bearing is in the transaxle and lubricated with transaxle oil.
- Remove the transaxle.
- 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.
- Remove the flywheel and the clutch disc.
- Use a small pry bar to remove the release plate retaining ring. Remove the release plate.
- 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.
- Use new bolts to attach the pressure plate to the crankshaft. Use a thread locking compound and tighten the bolts in a diagonal pattern to 22 ft. lbs. (30 Nm) plus 1 / 4 of a turn.
- LIGHTLY lubricate the clutch disc splines, release plate contact surface, and pushrod socket with multipurpose grease. Install the release plate, retaining ring, and clutch disc.
- Use special tool VW 547 or equivalent to center the clutch disc.
- Install the flywheel, tightening the bolts one or two turns at a time in a crisscross pattern to prevent distortion. Tighten the bolts to 15 ft. lbs. (20 Nm).
- Install the transaxle.
All VW models are equipped with a self-adjusting clutch cable. The VR-6 has a hydraulic clutch which is also self-adjusting.