Removal
1. Remove the transmission. Manual Transmission/TransaxleClutch Assembly Installation/Removal:
2. Mark the position of the pressure plate on the flywheel (arrow).
3. Remove the pressure plate from the flywheel using holding fixture VW 215c (gas), 3067 (diesel) or equivalent to secure the flywheel.
4. Loosen the pressure plate mounting bolts in a diagonal sequence, 1/4 turn at a time until the clutch pressure is relieved.
NOTE: On diesel engines, change retainer over when removing.
Pressure Plate:
5. Inspect the clutch pressure plate. Check the release levers for bending, misalignment, or scoring. If the release bearing contact surface on the release levers is scored deeper than 0.30 mm (0.012 in), the pressure plate should be replaced.
Pressure Plate:
NOTE: Clutch pressure plates have been modified for air cooled engines. Distance between fingers (a):
Old = 55 mm (2 3/16 in dia)
New = 46 mm (1 13/16 in dia).
Clutch Release Bearing:
6. On air cooled engine replace the release bearing.
NOTE: Release bearing with wider contact surface (arrow) is the only bearing available as a spare part. This release bearing will work with either old or new type pressure plates.
CAUTION: Do not install release bearing having a narrow contact surface together with short fingered pressure plate.
Pressure Plate Taper:
7. Using a straightedge, check that the mating surface does not taper inward more than 0.30 mm (0.012 in).
Pressure Plate:
8. Inspect the the clutch disc and pressure plate (arrows) for cracks, loose rivets, scoring, discoloration due to heat or oil contamination, and other damage. A pressure plate or clutch disc showing any of these signs of damage should be replaced.
9. Clean the flywheel friction surface and inspect it for wear, cracks, and grooves. Check for loose or worn dowel pins. Replace a flywheel with any of these faults.
Dial Indicator:
10. Check the thickness, runout, and general condition of the clutch disc. If runout exceeds 0.50 mm (0.020 in), or if there is any evidence of contamination by oil, the disc should be replaced.
NOTE: The clutch disc is a part which commonly wears out and requires replacement. Many experienced mechanics routinely install a new clutch disc anytime the transaxle is removed.
11. Inspect the splines of the clutch disc and the transmission input shaft. Check that the clutch disc is free to slide on the shaft. If the disc is in any way unserviceable, it should be replaced. Clean all traces of grease from the shaft and clutch splines.
NOTE: Presure plates are treated against corrosion, and greased. For maximum service life, clean only the friction surface of the pressure plate.