CLUTCH

Article Text
1998 Volkswagen Passat
This file passed thru Volkswagen Technical Site - http://volkswagen.msk.ru

ARTICLE BEGINNING

1998 CLUTCHES
Volkswagen FWD

Passat

DESCRIPTION

Clutch is a single disc type. A diaphragm spring is used to

engage pressure plate. The clutch system is hydraulically operated.
Clutch is controlled by clutch pedal, clutch master cylinder,
transaxle housing-mounted slave cylinder, release fork and release
bearing.

BLEEDING CLUTCH HYDRAULIC SYSTEM

Attach hose to bleeder fitting located on clutch slave

cylinder, next to hydraulic line. Submerge other end of hose in
container half full of clean brake fluid. Fill reservoir with DOT 3
brake fluid. Open bleeder fitting. Have assistant press clutch pedal
to full release position. Close bleeder fitting. Release clutch pedal.
Repeat until air bubbles no longer emerge from hose. Refill reservoir.

ADJUSTMENTS

* PLEASE READ THIS FIRST *

NOTE: Clutch system is automatically adjusted and requires no

manual adjustment.

GEARSHIFT SELECTOR

1) Place gearshift selector in Neutral position. Carefully

pry shift boot from center console. Remove gearshift knob and boot.
Remove 2 nuts and rubber cover from gearshift selector housing. See
STEP 1 in illustration. See Fig. 1.
2) Measure distance between body and gearshift selector
assembly. See STEP 2 in illustration. See Fig. 1. If distance is 1.46"
(36.9 mm), no adjustment is necessary. If distance is not 1.46" (36.9
mm), go to next step.
3) Loosen push rod bolt. See STEP 2 in illustration. See
Fig. 1. Set distance between body and gearshift selector assembly to
1. 46" (36.9 mm).
Tighten push rod bolt to specification. See
TORQUE SPECIFICATIONS. Go to next step.
4) Loosen gearshift selector ball housing nuts. See STEP 2 in
illustration. See Fig. 1. Position gearshift selector in Neutral
position. Tighten selector ball housing nuts. Loosen selector rod nut.
Position gearshift selector slightly towards rear of gearshift housing
and go to next step.
 5) Measure distance on both sides of gearshift selector. See
STEP 3 of illustration. See Fig. 1. Adjust distance so both sides are
equal. Tighten selector rod bolt to specification. Go to next step.
6) Check gearshift selector operation. With gearshift
selector in Neutral position, gearshift selector should rest in
3rd/4th gear gate. Depress clutch and select all gear positions
several times. Pay particular attention to reverse gear operation.
7) Gearshift selector should move from 5th/reverse gear gate
into 3rd/4th gear gate on its own. Gearshift selector should engage
smoothly when selecting gears. If gearshift selector operates as
specified, procedure is complete. If gearshift selector does not
operate as specified, go to next step.
8) Loosen gearshift selector ball housing nuts. See STEP 2 in
illustration. See Fig. 1. While pushing gearshift selector to right
side stop, push gearshift selector ball housing to left against
gearshift selector. Tighten gearshift selector ball housing nuts to
specification. Repeat steps 6) and 7) to verify proper gearshift
selector operation.
Fig. 1: Adjusting Gearshift Selector
Courtesy of Volkswagen United States, Inc.

REMOVAL & INSTALLATION

* PLEASE READ THIS FIRST *

NOTE: On models with theft protection system, obtain radio

security code from vehicle owner before disconnecting
battery cable.

CLUTCH ASSEMBLY

Removal
1) Turn ignition off. Disconnect negative battery cable.
Partially drain cooling system. Remove coolant reservoir. Remove
intake air hose. Raise and support vehicle. Remove right front wheel.
Remove upper transaxle-to-engine bolts.
2) Remove engine undercover and undercover bracket. Remove
front exhaust system with catalytic converter. Remove shields from
above right and left inner CV joints. Disconnect axle shafts at
transaxle flanges and wire axle shafts up as high as possible.
3) Disconnect starter wiring and remove starter. Disconnect
gearshift selector rods from top of transaxle. Disconnect connectors
for vehicle speed sensor and reverse lights at transaxle. Remove all
remaining transaxle-to-engine bolts except bottom 2 bolts. See Fig. 2.

Fig. 2: Identifying Transaxle-To-Engine Lower Mounting Bolts

Courtesy of Volkswagen United States, Inc.

4) Support transaxle with transmission jack. Remove transaxle

right support bracket and mount. See Fig. 3. Remove transaxle left
support bracket-to-mount bolt. Remove lower transaxle-to-engine bolts.
See Fig. 2. Separate transaxle from engine and lower transaxle until
clutch slave cylinder is accessible.
5) Remove clutch slave cylinder mounting bolts. It is not
necessary to disconnect clutch slave cylinder hydraulic line. Secure
clutch slave cylinder aside. Ensure all wiring harness connectors and
grounds necessary to remove transaxle are disconnected.
6) Carefully lower and remove transaxle from vehicle. Remove
pressure plate bolts. Remove pressure plate and clutch disc. See
Fig. 4.

Fig. 3: Identifying Transaxle Support Mounts & Brackets

Courtesy of Volkswagen United States, Inc.
Fig. 4: Exploded View Of Clutch Assembly
Courtesy of Volkswagen United States, Inc.

Inspection
1) Inspect pressure plate surface for wear, cracks, burning,
or warpage. Measure warpage with straightedge and feeler gauge at
several different points. Maximum pressure plate warpage is .008" (.2
mm). Inspect clutch release bearing for smooth operation and
looseness. Replace bearings if necessary. DO NOT wash release bearing
in solvent.
2) Inspect clutch disc lining for excessive wear and burned
or oil-soaked condition. Inspect clutch disc for loose rivets and
torsion dampers. Measure clutch disc and flywheel runout. Inspect
flywheel ring gear teeth for wear and damage. Inspect flywheel for
wear, cracks and burned condition.

NOTE: Pressure plate has a protective grease coating. Remove

contact surface grease only. Service life will be shortened
if remaining portions of pressure plate protective grease
are removed.

Installation
1) Replace input shaft "O" ring. See Fig. 5. To install,
reverse removal procedure. Apply grease to ball stud and inner surface
of release bearing. Clean hub splines of input shaft and apply a light
coat of grease. Ensure clutch disc slides on input shaft spines.
2) Install pressure plate bolts finger tight. Using Clutch
Centering Plug (3176), align clutch disc and pilot bushing holes.
Tighten pressure plate bolts to specification using a crisscross
pattern.
3) Ensure transaxle oil level is correct. Tighten flywheel
bolts to specification (if removed). Tighten transaxle-to-engine bolts
to specification. See TRANSAXLE-TO-ENGINE TORQUE SPECIFICATIONS table.
See Fig. 6 or 7.

TRANSAXLE-TO-ENGINE TORQUE SPECIFICATIONS

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Bolt No. Bolt Size Ft. Lbs. (N.m)

1.9L (1)
1 ........................ M 12 X 75 ................... 48 (65)
 2 ....................... M 12 X 110 ................... 48 (65)
3 ........................ M 12 X 90 ................... 48 (65)
4 ........................ M 12 X 67 ................... 48 (65)
5 ....................... M 10 X 135 ................... 33 (45)
6 ........................ M 10 X 45 ................... 33 (45)
2.8L (2)
1 ........................ M 12 X 67 ................... 48 (65)
2 ........................ M 12 X 90 ................... 48 (65)
3 ........................ M 12 X 80 ................... 48 (65)
4 ........................ M 10 X 45 ................... 48 (65)
5 ....................... M 10 X 135 ................... 48 (65)

(1) - See Fig. 6.

(1) - See Fig. 7.
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Fig. 5: Identifying Clutch Release Components

Courtesy of Volkswagen United States, Inc.
Fig. 6: Transaxle-To-Engine Bolt Identification (1.9L Engine)
Courtesy of Volkswagen United States, Inc.

Fig. 7: Transaxle-To-Engine Bolt Identification (2.8L Engine)

Courtesy of Volkswagen United States, Inc.

CLUTCH MASTER CYLINDER

Removal & Installation

1) Remove protective housing for control modules and set
aside. Pull and remove master cylinder fluid supply hose from brake
fluid reservoir. Plug reservoir. Remove remaining hydraulic line from
master cylinder. Remove cover below instrument panel.
 2) Disconnect master cylinder push rod from clutch pedal.
Working from inside of vehicle, remove mounting nuts and master
cylinder. To install, reverse removal procedure. Bleed hydraulic
system. See BLEEDING CLUTCH HYDRAULIC SYSTEM.

NOTE: Clutch slave cylinder removal and installation procedures

are not available.

OVERHAUL

NOTE: Manufacturer recommends replacement of faulty clutch master

and release cylinders and does not provide overhaul
procedures.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
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Application Ft. Lbs. (N.m)

Axle Shaft-To-Transaxle Flange Bolt ........................ 33 (45)

Clutch Master Cylinder Bolt ................................ 15 (20)
Clutch Release Cylinder Bolt ............................... 18 (25)
Flywheel-To-Crankshaft Bolt
Step 1 ................................................... 44 (60)
Step 2 .......................... Additional 1/4 Turn (90 Degrees)
Gearshift Selector Assembly
Ball Housing Nuts ........................................ 18 (25)
Push Rod Bolt ............................................ 18 (25)
Selector Rod Bolt ........................................ 18 (25)
Pressure Plate Bolt .................................... (1) 18 (25)
Starter Bolt ............................................... 48 (65)
Transaxle Oil Fill Plug .................................... 18 (25)
Transaxle-To-Engine Bolt ....................................... (2)

(1) - Tighten bolts in a crisscross pattern.

(2) - See TRANSAXLE-TO-ENGINE TORQUE SPECIFICATIONS table under
REMOVAL & INSTALLATION. See Fig. 6 or 7.
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END OF ARTICLE