Question about 1998 Volkswagen Passat

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1994 chev. diesel 4x4 clutch replacement how to

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First lift truck high enough so when transmission comes down you can get it out from under truck disconnect both negative cables remove rear and front drive shafts disconnect linkage to transfer case there are 6 bolts around transfer case adapter plate that come out to remove transfer case some models the lower bolt is blocked by the mount if so support transmission and remove cross member once transfer case is out of the way. celebrate with a quick beer. Now comes the hard part lower down and remove shifter tower usually four bolts if part of top cover then remove floor cover and boot press down on center cap and turn CCW to remove spring cover shifter will come out. remove bolts that hold rock cover on front of bell housing remove slave cylinder then remove the 6 bolts that hold bell housing to engine. slowly pull transmission back to separate form engine. once out high five your helper. remove the 6 bolts or 8 bolts that hold pressure plate to flywheel and now both plate and disc are off. Inspect flywheel for burnt spots any have flywheel resurfaced . replace pilot bearing ( needle) bearing type requires a blind hole puller. bronze bushing types thread a tap into back off crankshaft as it cuts threads and bottoms out it will remove the bushing. Most clutches come with a alignment tool. Install new pilot bearing apply a small amount of grease. Using the alignment tool to hold disc then install pressure plate THIS PART IS IMPORTANT slowly cinch down the bolts with a 1/4 inch nut driver by hand by cross tightening cover if you dont do this clutch will chatter because you bent the cover once close enough use a ratchet and 1/4 quarter turn until tight TAKE YOUR TIME DO THIS ONCE. Now tighten bolts to a torque of 30-35 ft lbs. I forgot dont let the alignment tool sag as you tighten up cover make sure this tools slides in and out easily once done replace release bearing and inspecting transmission front collar for wear if bad replace collar release bearing has a groove inside of it make sure that it is full of grease. apply a thin coat very thin to shaft. remove the beer cans from under truck and install in reverse order . good luck if this is your first clutch it will take a weekend.

Posted on Apr 20, 2014

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