nd 12 K for 3 Clutch Control Index Water-Cooled Gasoline — Brake/Clutch fluid reservoir 30.3 — Clutch assembly 30.4 controls 30,2 diaphragm spring 90.6 ise 90.7 hydrautle system 30.2 pressure plate 30.6, 30.7 ~ Release shaft bushing 30.3 — Rall pin 30.3 Diesel — Brake/Clutch fluid reservoir 30.3 — Clutch assemty 30.5 controls 30.2 diaphragm spring 30.6 disc 30.7 hydraulic system 30.2 pressure plate 30.6, 30,7 ~ Release shaft bushing 30.3, = Roll pin 30.3. AirCooted = Broke/Clutch fluid reservoir 30.3 = Clutch assembly 90.4 controls 30.2 diaphragm spring 30.6 disc 30.7 hydraulic system 30.2 Pressure plate 90.6, 30.7 modification 30.6, 30.7 ~ Rolease bearing 30.7 = Rolease shaft bushing 30.3 = Roll pin 30.3 Al 30.130 Clutch, Controls Sian aarance between push rod and WARNING piston in cluten master evindor Brake fluid Ia poleon 8.8mm (0.020 in) max ' - \ tC Patahation position Fig. 1 Gattae fl iGSteata with MoS: grease : rameve tein vw 207, natal lush Note Filling of system is done by removir top of dashboard and adding approv brake fluid (see caution page 30.5) t brake/cluteh fluid reservoir 25 Nm (18 ft Ib) Rubber stop Return apring sgh tan sig gh tee Bleeder screw My ‘open valve oly when Coupling bleeding hydraulic system, Bleed system only with pressure bieeder Roleaee shat ubrcate with Moss groase Hose 225 Nm (18 ft Iby I ease BeEMigntiy ASB roptace Cig <——~ ean boon HfaGrtfnta cis and So morgan in Soe attach with vtees® Saya pia sur Bushing’ with MoS2 grease roplacing, Fa. S and page 30.2 suirryasuicersnm [a-speed 091-091/1] S-speed 08isonous noving cover pproved type 0:9)10 tnger nsen ‘t fe Aetna ree 5b 8 81) , smn ver surces pd page 90.78 a2 Clutch, Controls 3C Fig. 1 Roll pin, installation position ‘(oll pin must be engaged in groove (arrow) on side of bracket CAUTION Brake fluid must not come into contact with paint. Brake fluid absorbs moisture trom air and must be replaced every 2 years. Only use new unused OOT 3 or DOT 4 bake fhuid according 10 MOTOR VEHICLE SAFETY STANDARD 118, Do not add or nix DOT § silicone type brake fluid with brake fluid in car, as severe component carrosion may regult, Such corrosion could lead 10 clutch and brake system failure Fig. 2 Brake/clutch fluid reservoir, fi ~ grasp two recesses on back of dashboard cover and pull up — ill with brake fluid (see above caution) Until level is between “MAX” and MIN" — replace cover by inserting tront edge first then press cover down firmly VW771/15 Fig. 4 Release shaft bushing, Installing drive in flush Fig. 5 Release bearing, installing — new release bearings on which thrust ring is not centrafty positioned to housing (arrow) can be installed = thrust ring automatically centers itseit ‘Of frst application of clutch pedal ‘3 |4-speed 091-091/1| _5-speed 094 Roll pin Brake/clutch fluid reservoir 30. Rolease shaft bushing P30 Clutch, Controls Note Only transmission must be removed for clutch repairs ing . 25 Nm (18 ft 1) ‘Clutch diaphragm spring Jooten and tightan by stages in diagonal checking fingers Fig. 3- Fig. 6 sequence Note Install hexagon bolts or socket head ‘Spring finger length increased screws MB x 18 without spring check far compotitie release washer; or bearing — install Rexagon bolts or socket head screws MB x 18 with spring washer use only bolts or screws of same length 0 a ‘Clutch pressure plate { ‘emovinghestaling ig 7 WARNING checking Fig. 7 and Fig: 8 Friction materials such as brake and clutch linings or brake pad may contain asbestos fibers. Do not create dust by grinding, sanding or by cleaning ‘with compressed air. ‘Avoid breathing asbestos fibers and asbestos dust. Breathing asbestos may result in serious diseases, such as asbestosis or cancer. Breathing asbestos may cause severe injury and death. 304 cuss, | Ses0ine |Clutch * Ch de hing Fig. 9 50-00 Aa ‘Clutch prossure plate remavingitnstalling Fig. 2 checking Fig. 7 and Fig 8 for correct position of TDC mark ‘on pressure plate) Clutch diea centering Fig. 2 chocking Fig. 9 instalation position: spring cage feces pressure plate 25 Nm (18 ft 1b) Joosen and tighten by stages and in diagonal sequence —install hexagon bolts oF socket head screws: Note Mx 16 without spring washer; or install Nexagon bolts or socket head screws For clutch repairs, transmission must M8 x 18 with spring washer be removed —use only bolts or screws of same length sel | cursnassendy GOD30 ciutch removing! installing — attach flywheel retainer WW 215¢ — mark position of pressure plate on tiywheel (arrow) ~ loosen bolls diagonally Fig, 4 Clutch pressure plato, 228 mm (9 in.) dia {modification only for air-cooled vehicle distance a between fingers: was = 55mm (2 3/16 in.) dia, Ie now = A@menr (1 13/16 in.) dia, Fig. 2 Clutch atsembly, Diesel & removing/installing Fig. 5 Production release bearing, air-cooled ‘contact surface diameter is 46 mm (' —change retainer aver when removing Fig. 3 Clutch diaphragm spring, checking fingers * scores (arrows) up to depth of 0.3 mm (0.012 in) are OK Clutch dise 30.6 sucrmessuesas, | [4-speed 091-091/1] §-speed 094Clutch SC Fig. 6 Replacement (073) ase bearing, air-cooled engines Note Release bearing with wider contact surface (arrow) is the only bearing available as spare part. This release tearing will work with either old or new type pressure plates. Engine replacement If exchanging engines, be sure that wider-contact- surface release bearing is used it pressure plate i= of older type [where a, Fig. 4, = 55mm 12 3/16 in.) dia) CAUTION Do not install release bearing having narrow contact surface (46 mm (1 13/16 in.) di together with short fingered pressure plate [a= 85 mm (23/16 in.) dial Fig. 7 Clutch pressure pl " checking = check straps (black arrows) between plato and cover tor cracks and tightness of rivets (white arrows} «clutches with (oose or damaged rivets must be replaced Fig. 9 Clutch disc, cttecking/instatling Fig, 8 Clutch pressure plate, checking — check for cracks, burn marks and wear ‘Inward taper: 0.3 mm (0.02 in.) max. = check runout: 0.5 mm (0.020 in.) max, © measured 2.5 mm (3/32 in) from edge of dise — check finiag and splines for wear and fivets for tightness, ‘when installing, clean corrosion trom transmission mainshatt and clutch dise splines — lightly tubricate clutch splines with grease © use grease part ao. G 000 100 = place transmission into gear to tock mainshaft and temporarily instal clutch disc to check movement ‘© spring cage must face pressure plate © clutch disc must slide treely on mainshatt — remove excess grease Clutch —_—— case bearing 4-speed 091-091/1 speed 094 lath oes pate 30.730 clutch Fig. 10 Release bearing, installing ‘© New release bearing on which thrust ring is not centrally positioned to housing (arrow) can be installed © thrust ring automatically centers itself ‘on fist application of clutch pedal 30.7 citer retooe eningClutch, Controls 30 Note Clutch, bleeding For repairs on release bearing and release shaft, Connect brake bleeder US 1116 remove transmission. For repairs on foot pedals, Operating pressure = 2.2.5 bar. femove instrument panel. Leave bleeder valve open untit brake fluid drains without any bubbles. Cleve cotter pe ‘jut unt clearance between push rod alvaye re land clutch maser cylinder piston equals ‘a maximum of 0 mm sf ————haat pin e od instalation positon Fig. 1 Shen Bushings remove with VW 207 instal fush Clutch pedal ‘Chitch slave cylinder before installing, insert rear bolt Slave cylinder bracket -45 Nom (33 ft 1b) 15 Nm (tt fe tb) Guide sleeve ‘grease metal sleove with Mo Do not grease plastic sieeve 15 Nm (11 ft 1b) Bushing removing Fig. 2 Installing Fig. 3 Pressure hose 8 25.Nm (18 ft 1b) lp Ciretip siways replace Clutch lever lightly lubricate bal Release shatt bearing Release bearing Wipe dry, do not use solvent Lubricate pivot surface with MoS. grease replacing, Fig. 4 Rolease shatt install with multi-purpose grease ‘Spring etip insert into clip and attach with release bearing and clip to release shatt sore [Smee] eaezee: 30.830 Clutch, Controls Fig. 1. Roll pin, installation position roll pin must be engaged in groove (arrow) on side of bracket Fig. 2. Release shaft bushing, removing A — inner extractor 18.5-23.5 mm eg. Kukko 21/3 Fig. 3. Bearing shaft bushing, installing — push bushing in to stop Fig. 4 Release bearing, installing New release bearing on which thrust ring is not centrally positioned fo housing (arrow) can be installed. ‘The thrust ring automatically centers itsalf on first application of clutch pedal Fol pin Release shaft bushing 30.9 Ssesnuan LemClutch, Controls 30 ‘CAUTION Clutches with damaged or loose riveted ‘connections should be replaced. Note Remove engine when working on the clutch CAUTION When replacing engines, transmissions or clutches, make sure the diameter and joint surfaces of release bearing and diaphragm spring match, centering checking ‘ransmissi ‘splines. Li toe 25 Nm (18 #18) loosen or tighten diagonally in stagos Pressure plate emoving and instaling Fig, 1 checking for woar and warping Figs. 2, 3 and 4 Clutch disc Fig. 1 runout Fig. 5 Note instalation postion, spring cage faces pressure plat. ‘When instaling, clean corrosion from jon mainshaft and clutch hub ightly grease clutch splines with grease, part no. G 000 100 chock that spring pin fits tightly Clutch facing contact surface must be ‘of cracks, oll and grease cusen saeonoy 30.1030 Clutch, Controls Fig. 1 Clutch removing/installing — mark installation position (arrow) — check straps between pressure plate and cover for cracks and loose rivets (arrows) © clutches with damaged or loose riveted sections should be replaced Fig. 2 Clutch diaphragm spring, checking — examine fingers (arrows) © scores up to a maximum of 0.3 mm are acceplable Fig. 3 Cluteh, checking Fig. 4 Pressure plate, checking — check pressure plate for cracks, bum marks and distortion ‘© maximum inward taper = 0.3 mm, Fig. 5 Clutch disc, checking runout ‘© maximum runout = 0.5 mm (measure 2.5 mm from outer edge) rae 30.11 Saeer Synero