Removal and installation the clutch (VW Passat B4)

To remove the clutch, remove the gearbox as described in the subsection "Removal and installation the gearbox".

If further use of the clutch is intended, mark the position of the clutch housing on the flywheel.

Loosen the bolts securing the clutch housing to the flywheel and remove the housing together with the driven disk. This will release the driven clutch disk. Clean the clutch parts thoroughly. Use a straightedge and feeler gauge to check the flatness of the working surface of the pressure plate.

Check the degree of wear of the pressure spring at the point of contact with the clutch release bearing. Using an indicator, check the degree of wear of the friction linings of the driven disk at a distance of 2.5 mm from the disk circumference. Clean the friction surface of the pressure plate. Cleaning other clutch parts is not required, as they are protected from corrosion.

Check the condition of the splines in the driven disk hub and on the gearbox input shaft, clean the splines and lubricate with a thin layer of molybdenum disulfide-based grease.

Install the clutch, positioning the driven disk with the protruding part of the hub towards the pressure plate, and center the disk relative to the flywheel with a mandrel (fig. 4-3 and 4-4), simulating the splined end of the primary shaft of the gearbox.

Install the clutch, positioning the driven disk with the protruding part of the hub towards the…

Tighten the clutch housing mounting bolts crosswise to 2 kgf·m. Remove the mandrel. Check the condition of the clutch release bearing and replace it if necessary.

Apply a thin film of grease to the sliding surface of the clutch release bearing in the guide sleeve. Install the gearbox as specified in subsection "Removal and installation the gearbox".