Contents - Volkspage

6.2 Clutch
Refitting
5 Refitting is a reversal of removal, but note
the following points:
a) Make sure the flats on the cable are located
correctly on the steering gear housing.
b) Grease the cable attachment point on the
pedal, but do not grease the cable before
fitting it to the steering gear housing, as
there is a danger of grease blocking the
breather vent.
c) Check that the clutch operates correctly:
depress the pedal several times, then pull
the release lever approximately 10 mm
away from the cable to check that it is free.
Removal
1 Disconnect the clutch cable from the
release arm on the transmission clutch
housing and from the top of the clutch pedal
with reference to Section 3.
2 Prise the clip from the end of the pedal
pivot shaft.
3 On left-hand drive models, withdraw the
pivot shaft just enough to allow the clutch
pedal to be removed from the bracket. On
right-hand drive models, the pivot shaft must
first be withdrawn through the brake pedal.
4 Clean the pedal and pivot shaft and
examine them for wear. If the bushes are worn
they can be removed using a soft metal drift,
and the new bushes installed using a vice to
press then into position. Check the rubber
foot pad and the stop rubber on the bracket,
and renew them if necessary.
Refitting
5 Refitting is a reversal of removal, but apply
a little multi-purpose grease to the pivot shaft
and bushes.
torsional damping springs and protrudes by a
greater amount - this side faces the pressure
plate.
5 Check the condition of the clutch
components as described in the following
sub-Section.
Inspection
6 Examine the surfaces of the pressure plate
and flywheel for signs of heavy scoring. Light
scoring is normal, but if excessive the
pressure plate must be renewed and the
flywheel either machined or renewed.
7 Inspect the ends of the pressure plate
diaphragm spring fingers; look for wear
caused by contact with the release bearing. If
the scoring appears excessive, renew the
assembly.
8 Using a straight edge and feeler blade,
check that the inward taper of the pressure
plate does not exceed the maximum amount
given in the Specifications (see illustration).
Also check for loose riveted joints and for any
cracks in the pressure plate components.
9 Check the driven plate linings for wear; renew
the plate if the linings are worn to within 1.0 mm
(0.04in) of the lining material securing rivets.
10 Check that the driven plate damper
springs and all rivets are secure, and that the
linings are not contaminated with oil.
Temporarily fit the disc to the transmission
input shaft and check that the run-out does
not exceed that given in the Specifications.
11 If the clutch components are
contaminated with oil, the leak should be
found and rectified. The procedure for
renewing the crankshaft oil seal is described
in Chapter 2A; the procedure for renewing the
transmission input shaft oil seal is described
in Chapter 7.
12 Having checked the clutch disc and
pressure plate, check the release bearing with
reference to Section 7.
Refitting
13 Before commencing the refitting
procedure, a tool must be obtained for
aligning the driven plate, otherwise difficulty
will be experienced when refitting the
transmission. If the driven plate is not aligned
centrally before the pressure plate is fitted, it
will not be possible to engage the
transmission input shaft with it. If a
centralising tool is not available, a wooden
mandrel may be made to the dimensions
shown (see illustration).
14 Clean the friction faces of the flywheel
and pressure plate, then fit the centralising
tool to the crankshaft and locate the driven
plate on it with the hub extension facing
outwards (see illustration).
15 Fit the pressure plate assembly to the
flywheel (using the alignment marks made
during removal, if the original component is
being refitted). Ensure that the friction surface
lies flat against the driven plate, then insert
the retaining bolts and tighten them
progressively in diagonal sequence to the
specified torque (see illustration).
16 Refit the transmission as described in
Chapter 7, then reconnect the clutch cable as
described in Section 2.
Removal
1 Remove the transmission as described in
Chapter 7.
2 Mark the position of the pressure plate
cover with respect to the flywheel, to ensure
correct alignment on refitting.
3 Using an Allen key or hex bit, unscrew the
pressure plate bolts progressively in a
diagonal sequence (see illustration). If
necessary, prevent the flywheel from rotating
by inserting a screwdriver between the starter
ring gear teeth and the cylinder block.
4 Withdraw the pressure plate assembly and
the driven plate from the flywheel. Note that
one side of the pressure plate hub houses the
4.3 Removing the pressure plate bolts 4.8 Checking the clutch pressure plate
for taper
4.13 Clutch driven plate centralising tool
dimensions
A 18.24 mm B 70.0mm
C 20.0mm D 14.81 mm
4.14 Driven plate fitted
with centralising tool in place