Clutch replacement for the vw golf and jetta

[fismail]

On older (1985-’89) VW Golf, GTI and Jetta models, clutch engagement and release problems can be caused by an improperly adjusted clutch linkage. One of two different types of clutch cables (which are not interchangeable) may be used on these applications. One is a manually adjusted cable that requires periodic adjustment to compensate for clutch wear. The other is a self-adjusting cable that can be identified by a rubber boot atop the clutch cable sleeve on the transaxle end of the cable.
On the adjustable variety, clutch freeplay should be measured at the large plastic disc that butts up against the rubber cable grommet on the transaxle, not at the sleeve. Volkswagen issued a technical service bulletin on this item (TSB 88-01) because technicians were breaking the sleeve by trying to check the adjustment at the sleeve instead of the disc.
To adjust the linkage:
1. Work the clutch pedal several times. Then raise the clutch release lever by hand until resistance is felt.
2. Check the freeplay adjustment by measuring the distance between the transaxle housing and the large plastic disc on the cable. Volkswagen calls for a clearance of 12.0 mm (15/32 inch). VW has a special tool gauge (US 5043) that can be slipped between the disc and transaxle to check clutch freeplay.
3. If the cable needs to be adjusted, loosen the locknut under the adjusting sleeve and turn the sleeve as needed until the specified clearance is obtained. Then hold the sleeve and tighten the locknut to 4-6 Nm (36-48 in. lb.).
If a cable is broken, binding or corroded and has to be replaced, a manually adjustable cable can be removed by loosening the adjusting sleeve and backing off the sleeve until the cable’s tension is relieved. The clips that attach the cable to the release lever can now be removed and the cable disconnected.
To remove a self-adjusting cable, the spring under the rubber boot must be compressed before the clips that hold the cable to the release arm can be removed and the cable disconnected from the arm. Do not open the automatic adjuster mechanism. VW says if the adjustment mechanism is opened, the cable assembly has to be replaced.
The clutch assembly in VW Golf, GTI and Jetta models is unusual in that the clutch bolts to the crankshaft and the flywheel bolts to the clutch. It also does not have a conventional release bearing. The release arm works a small lever in the release housing on the transaxle that pushes a small bearing against the end of a long pushrod. The pushrod runs through the middle of the transaxle mainshaft and pushes against a "release plate" over the clutch. When the pushrod moves toward the engine, the release plate presses against the clutch diaphragm to release the clutch.
If dirt gets in between the pushrod and transaxle mainshaft, it may cause the pushrod to bind in the released position, causing the clutch to slip. If the pushrod wears through the release plate or the lever arm in the transaxle release mechanism is broken, the clutch may fail to release when the clutch pedal is depressed. In either case, the pushrod and release mechanism should be inspected to determine the cause.
When servicing the clutch, the release rod bearing, located at the rear of the transmission under the round, sheet-metal cover, should always be replaced along with the other clutch components. The sheet-metal cover can be easily bent during removal and may also have to be replaced. Other items that should be replaced are the seal and bushing that prevent transmission oil from leaking into the transaxle and contaminating the clutch. Also, inspect the release rod for wear or distortion, and replace it if either condition is found.
VW uses a stepped flywheel on these cars, so that when the flywheel is resurfaced, equal amounts of metal must be removed from both surfaces to maintain the proper clutch height and pressure. If only the inner face is resurfaced, the clutch will not exert enough pressure against the disc, which may allow it to slip, overheat and wear.
If you’re installing a new flywheel because the old one is cracked, damaged or too badly worn to be resurfaced, you should know that some replacement flywheels may not have an ignition timing mark. If there is no mark, you’ll have to make one by filing a notch 12 mm (0.472 inches) to the left of the Top Dead Center mark.
Position the clutch pressure plate on the crankshaft. Apply threadlocking compound to new bolts, and install and tighten the bolts without shoulders to 75 Nm (55 ft. lbs.) or bolts with shoulders to 100 Nm (72 ft. lbs.). VW released a bulletin (92-02) that revises the bolt torque specs on 1987 and up Golf, and 1989 and up Jetta (and Passat). The bulletin says to tighten the bolts to 60 Nm (44 ft. lbs.), then turn them an additional 1/4 turn (90 degrees).
Next comes the release plate. The center contact for the pushrod should be lightly lubricated with lithium grease. The retaining ring should be aligned so the open ends are over one of the holes in the plate.
The clutch disc can then be placed inside the flywheel, and the flywheel bolted onto the pressure plate. You’ll need a special centering tool because an ordinary pilot tool won’t work on this application. VW’s clutch centering tool for 1.8L SOHC engine applications is VW 547, while the one for the 1.8L DOHC 16-valve engine applications is P/N 3178. Use the tool to hold the disc in place while the flywheel bolts are tightened evenly in a star pattern to 20 Nm (15 ft. lbs.).