The clutch is a single dry disc type, using a diaphragm
spring type pressure plate and a clutch release bearing mounted inside the transaxle. The clutch is cable operated.
PEDAL TRAVEL ADJUSTMENT
1) Hook a tape measure over top of clutch pedal pad. Tape
hook to pad to hold it in place. Pull tape through steering wheel and record measurement at centerline of wheel rim. Fully apply clutch pedal. 2) Record measurement at centerline of wheel rim. If difference between 2 measurements is 4.6" (117 mm) or more, adjustment is correct. If difference is less than 4.6" (117 mm), remove push nut from stud behind pedal bracket. 3) Remove left scuff plate from driver's door. Separate carpet from floor on driver's side wheelwell. Lay carpet into position and measure. If required amount of travel has been obtained, adjustment is complete. 4) If clutch pedal travel is still incorrect, remove portion of floor insulation that is between floorpan and area where pedal bottoms out. Reinstall carpet. No further adjustment is available.
NOTE: Transaxle is lowered out of vehicle. Engine remains
installed.
REMOVAL
1) Disconnect battery ground. Attach engine support assembly.
Remove left transaxle mount. Disconnect back-up light wires, speedometer drive cable (plug hole) and clutch cable. See Fig. 2. 2) Remove upper clutch housing-to-transaxle bolts. Remove starter. On models equipped with flywheel which has cut-outs, align flywheel lug with boss on bellhousing. On all models, disconnect shift linkage at rod lever and relay lever. Remove front selector rod.
NOTE: Vehicles with cut-outs in flywheel can be identified by a
stud/nut at right engine-to-transaxle mounting position. Flywheel of this type MUST be aligned before removing transaxle.
3) Remove exhaust pipe bracket. Remove transaxle rear mount
vehicles with cut-outs in flywheel, pull transaxle away from engine to
clear dowels. Lower and remove transaxle. On all other vehicles, pull transaxle away from engine while cocking engine so right drive flange clears flywheel. Lower and remove transaxle. 5) With transaxle removed from engine, install Holder (VW558) to ring gear or pressure plate. Pry retaining ring from release plate and lift release plate from pressure plate. Remove pressure plate bolts in a diagonal manner and separate clutch disc.
Fig. 2: Clutch Cable Routing & Adjusting Location
Courtesy of Volkswagen United States, Inc.
INSTALLATION
1) To install, coat pressure plate bolts with Loctite 270 or
CLUTCH RELEASE BEARING & RELEASE LEVER ASSEMBLY R & I
REMOVAL
1) Remove 4 bolts and washers mounting clutch release cover
to the far left end of transaxle case. Cover is waffle patterned. Remove 2 circlips from each side of clutch release lever. 2) Pull release lever and release shaft assembly out of case. Lift return spring along with release lever out of transaxle case. Remove release bearing, guide sleeve and push rod. Check seals and bearing. Replace defective parts.
INSTALLATION
1) Coat ends of push rod with multipurpose grease and insert
back into position. Grease sliding surface of bearing and guide sleeve. 2) Position return spring and release lever inside transaxle case. Return spring center hook should fit on top of release lever lug. Spring end hooks must point down to hold release lever away from release bearing. 3) Lightly coat release shaft with multipurpose grease and install. Work release lever until splines on release shaft mesh with release lever. Install circlips. Make sure return spring has tension. Install gasket and cover.
TORQUE SPECIFICATIONS
TIGHTENING SPECIFICATIONS TABLE
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Ft. Lbs. (N.m)
