Installation

*** THIS ARTICLE REFLECTS CHANGES MADE BY TSB # 348701, DATED JULY 31, 1987 ***.

1. Install the flywheel
2. Using VW Special Tool 10-201 to hold the flywheel, torque the flywheel bolts (without shoulder) to 75 Nm (54 ft lb), and bolts with shoulder to 100 Nm (72 ft lb).

NOTE: Install new bolts with D6 locking compound or equivalent.

Clutch Assembly:

3. Position the clutch disc and the pressure plate on the flywheel, aligning the marks made earlier.
4. Install the mounting bolts, leaving them loose enough that the clutch disc can still move.

NOTE: The projecting part of the clutch hub faces the pressure plate, away from the engine.

Clutch Centering Tool:

5. Center the clutch disc using VW Special Tool 10-213 or equivalent.
6. Tighten the pressure plate mounting bolts evenly just until the disc is held firmly in place.
7. Remove the centering tool.
8. Using VW Special Tool 10-201 to hold the flywheel, tighten all bolts evenly 1/4 turn at a time until the pressure plate is fully seated. Torque the bolts to 25 Nm (18 ft lb).
9. Thoroughly clean the splines of the clutch disc and mainshaft with a wire brush. Lubricate clutch components using lithium grease or equivalent. Ensure that the disc slides freely on the shaft before assembly.
10. Lubricate the release bearing contact surface on the release levers.

NOTE: Use only small amounts of the recommended grease on the splines. Otherwise, the clutch disc may bind on the input shaft and cause hard shifting. Other lubricants (or too much) may contaminate the clutch disc.

Clutch Release Shaft - Exploded View:

11. Inspect the release bearing. The bearing should rotate smoothly without any noise. A noisy or faulty bearing should be replaced.

CAUTION: Do not grease the guide sleeve. Do not clean the release bearing in solvent.

12. Reinstall the transmission. Manual Transmission/Transaxle