Clutch Removal

NOTE: When performing operations on the transaxle system that involve rotating or shifting the transaxle tube, always wear leather gloves to avoid injuries.





- Disconnect ground wire at battery.
- Disconnect ground wire connecting body with clutch housing.





- Disconnect ground wire on clutch housing I.
- Unscrew socket head bolts and run reference mark sensor II and speed sensor III for DEE out of holder IV.
- Disconnect wire harness for starter at upper mounting point V. If necessary, remove air cleaner for this step.











- Remove exhaust assembly. This requires unscrewing exhaust pipe on exhaust manifold and suspension mounting bolts. If car has oxygen control, disconnect wires of oxygen sensor on plug.





- Remove heat shield above catalytic converter.
- Remove splash guard.
- Loosen exhaust support bracket bolted on the central tube, and slide forward.
- Push back dust cover. Remove lockwire on clamp bolt of selector linkage. Unscrew bolt.





- Lift and fold down dust cover and sleeve on shift lever. Remove shift lever knob retainer. Take off shift lever knob.





- Remove circlip on shift lever. Pull off selector rod and washer on bolt of shift lever.
- Remove insulator above shift lever console. Remove shift lever, but first mark location of console after removing the rear mounting bolt.





- Press down on insulation sheet and push selector rod forward in cavity by about 300 mm (12 in.).





- Unscrew two upper mounting bolts of clutch housing.





- Take off end cap on central tube housing.
- Push back protective tube for selector rod far enough, that it is outside of the central tube housing. This is done by inserting a large screw driver through assembly opening in central tube housing and opening retainer on protective tube.





- Unscrew and remove clamping sleeve bolts through assembly openings. Push clamping sleeve in direction of transmission.
- Detach joint shafts on transmission end, but do not let joint shafts hang down to final stop in joint (instead suspend from car with wire) to avoid damage.





- Pull off wires on backup light switch. Also pull off plug on speedometer drive.
- Run in a workshop trolley jack fitted with Special Tool 9115 or an universal transmission jack underneath the transmission. Lift transmission slightly to remove pressure on suspension.

Initial Version:

Initial Version

Present Modified Version:

Present Modified Version

- Remove transmission suspension bolts.
- Lower transmission with central tube until central tube rests on the rear axle cross tube.

- Remove transmission/central tube flange bolts. Remove transmission downward.








- Remove starter. Unscrew clutch line mounting clamp. Detach clutch slave cylinder on clutch housing (do not open hydraulic system).





- Disconnect starter wire harness on clutch housing. Pull out release lever shaft mounting bolt with a 8 mm bolt. Unscrew the four central tube/clutch housing mounting bolts.
- Pull back selector rod again, which had been pushed forward for removal of the transmission, so that nothing will be damaged when moving the central tube.
- Move back central tube far enough until central tube housing rests on transmission carrier. If central tube cannot be moved out of clutch housing without applying force, hold engine tight with transport eye mounted on camshaft housing with Special Tool VW 10-222.
In this case the engine has excessive inclination at rear - check engine suspension.

NOTE: Make sure brake lines are not damaged by the central tube.





- Unscrew guard on clutch housing. Remove right support, insofar as car is fitted with supports.








- Unscrew two lower mounting bolts on clutch housing, after unscrewing engine mount nuts and pushing engine to the right.
- Move out guard and clutch housing with release lever.
- Disconnect clutch from flywheel.