Repairs to clutch (190/200 mm dia.) — VW

Note:

When repairs are required to the clutch, the gearbox must be removed =>page
34-17

TDC sensor adapter in clutch housing=>page 34-76

When removing and installing the clutch in addition to the notes in the Workshop manual the following should be noted:

Clean input shaft splines and with used clutch plates clean hub splines, remove corrosion and apply a very thin coat of G 000 100 grease to the input shaft, until the hub move freely on the shaft. Remove surplus grease without fail.

Caution!
Assemble clutch so that the centering pins in flywheel engage the centering holes or slots in the pressure plate. Otherwise the TDC mark on flywheel will no longer be correct.
Flywheel
Removing and installing - Fig.1
Ensure that centering pins are tight, contact surface for plate must be free of grooves, oil and grease.

Clutch plate
Centering - Fig. 2
checking for lateral run-out - Fig. 3
coat splines lightly with Molykote or Molyspray.

Retaining ring
Lever out with screwdriver watch position - Fig.4

Release plate
Coat contact surface and socket for clutch push rod lightly with lithium grease.

Screw M10 x 1 x 20
Renew, Installed with D6 locking fluid
With shoulder 100 Nm
Without shoulder 75 Nm

Packing plate
Pressure plate
Removing and installing
Checking - Fig. 6, pressure plates with damaged or loose rivets should be renewed.

Release plate
For 200 mm dia. clutch coat surface and socket for clutch push rod lightly with lithium grease.

Retaining ring
For 200 mm dia, clutch lever out with screwdriver, watch position - Fig. 5

Screw
M 7 x 40, 20Nm

Clutch push rod
Grease at bush location in drive shaft.

Fig.1
Removing and installing flywheel

Fig.2
Installing clutch plate

Tighten screws alternately and diagonally to 20 Nm

Fig.3
Removing and installing pressure plate

Note:

To fit the 200 mm clutch the retainer VW 558 must be reworked as shown in Fig. 9.

Fig.4
Installing retaining ring (190 mm clutch)

Watch position of ring ends.

Fig.5
Installing retaining ring (200mm clutch)

Watch position of ring ends.

Fig.6
Checking pressure plate for distortion, cracks and signs of burning

Maximum inward taper 0,2 mm.

Fig.7
Check spring connections between pressure plate and cover for cracks, loose rivets and security

Clutches with damaged or loose rivets should be renewed.

Fig.8
Checking clutch plate for lateral run-out

May. 0.3 mm (measured 2.5 mm from outer edge)

Fig.9
Reworking retainer VW 558

The shaded area must be reworked to dimensions given.

Note:

The 200 mm dia. clutch can be service installed by replacing the pressure plate, flywheel, clutch plate, release plate and retaining ring.