Section 8 MANUAL TRANSMISSION AND CLUTCH Contents troduction a 7.1. ‘Transmission Disassembly and Assembly... 22 Removing and Installing Sth Gear General Description. 4 Removing and Instaling Main Shaft and Gluteh 4 Pinion Shatt Transaxle 4 7.2 Transmission Gear Train Disassembly and As ve-Speed Manual Transiission 4 sembly 20 Dive a Synchronzers and Synchronizer Flings ...... 32 nttication Codes ana Speci 5 Bearings and Races 34 Asjusting Pinion Shaft Bearings 96 2, Maintenance 5 8, Final Drive 2, Tronbleshooting, a 8.1. Final Drive Removal and installation 34 Troubleshooting Prin 42 Final Drive Disassembly and Assembly... .. 38 32 Diagnostic . Ring Gear 22 ial Pinion Gears and Side Gears... 40 4. Shift Mechanism 7 and Races a 4.1 Disassembling, Assombiing, and Adjusting Shit ‘Adjusting Fina! Drive Bearing a 8 8. Technical Data 43 Remeving and instaling Shift Lever and Shit 1. Tightening Torques: 6 Fo ° il Transmission Codes and Gear Ratios 44 iL, Clutch 44 \V. Synchronizer Ring Wea Spectications “4 5. clutch 0 Pinon Shaft Bearing Turning Torque “4 5.1 Clutch Cable 0 Vi. Final Deve Beating Turning Torque “4 52 Removing and installing Clutch 2 TABLES 6, Transmission and Final Drive 15 a Manual Transaxle Specifications 8.1 External Adjustments 15 b. Manual Transaxle Troubleshooting 16 © Grelips tor Adjusting 3rd Gear End Play 13 4. Synclvonizer Ring Wear Spectteations 299. Shims For Adjusting Pinion Shalt Bearing Preload {Pinion Shaft Bearing Turning Torque 28 7. Transmission 223: Shirms For Adjusting Final Drive 2 h. Final Driva Bearing Turning Torque 43MANUAL TRANSMISSION AND CLUTCH = 8-3. Manual Transmission and Clutch Introduction ‘The five-speed ranual transmission, stanclarcl on the vehicles covered by this manual, is fully synchronized in all forward gears. A two-piece lightweight aloy case houses both the gear train and the final dive. AS a unit, the transmission, the final drive, and the case are called the transaxle. From the transaxle, power is transmitted to the drive wheels by the drive ales and constant velocity joints, The service and repair of drive axles and constant velocity joints is covered in SUSPENSION AND STEERING. Because of the transverse engine mounting, the transmission of power from the transis sion to the differential is by spur gears, rather than by bevel gears the kind used in other Yoksiagen transaxies. The transaxieis also unique in that the mainshefts hollow, allowing the clutch pushrod to pass through its center. ‘The transaxie can be removed and installed without removing the engine, oF the engine and lransaxie can be removed as.a unit, using the procedure given in ENGINE, and separated later. ‘Though internat repair of the transaxle requires specialized knowledge and equipment, Significant expense may be saved by removing and instaling the transaxle, using the proce: dures described in this section, Onoe removed and cleaned, the transaxie can be taken to an authorized Volkswagen dealer or other qualified shop for repairs. A parlally disassembled lwansale in a box is a mechanic's nightmare, and partial disassembly is not a way to save ‘money, D0 not attempt to begin a job which cannot be propery finished. It performing work on the transaxle, make sure that the correct tools are available before beginning the jcb-~ particuasly for procedures given only with matic specications, Volkswa- {gen vehicles, and especially thai crvetrains, are covered by an extensive new-car waranty, We urge you to consult an authorized Volkswagen deale: belore beginning any repairs on a car Which may stil he covered by the new-cae warranty.8-4 MANUAL TRANSMISSION AND CLUTCH 1, GENERAL DESCRIPTION Fig. 11 is cross-section of the transaxle with five-speed manual ransmission, The goars on the mainshaf and tne drive pinion shaft are called the transmission gear tin. The dive, pinion, the ring gear, and the citferential gears all of which cary crving forque fern the transmission gear train tothe front whee! driveshafts are called the final drive 1.4 Clutch ‘The clutch is cable-operated. Two types of clutch-actuating cable are used on cars covered by this manual. On some later models, the conventional clutch cable has been upgraded with aselfadjusting mechanisra. The clutch release mechanisen, on the crivers side of te transaxle, activates a push rod through, ja hollow mainshatt. This pushrod moves the retease plate of the pressure plate assembly fo engage or disengage the clutch, ‘Thepressure plate assembly consists of diaphragm-spring type pressure plate, a release plate, anda retaining ing to hold them together. The friction clutch disc is splined to accept the ‘nainshait of the transmission and has integral cushion springs and dampening springs. The cushion springs—which are be tween the fiction surfaces of tha disc help to reduce the shock when the clutch is engaged, The dampening springs ‘which afe visible in the center nub — help to absorb the rotating ower pulses of the engine, Unlike mest other cars, the clutch’s pressure plate assembly is bolled to the crankshatt with the flywhee! bolted to the periphery ofthe pressure plate assembly. The ring gear, used 19 engage the starter. i integral with the fiywhee! and cannol be separated. Trenton cite 1.2 Transaxle The transade case, which contains the transmission gear train and the final drive gears, is a lightweight allay die casting with an integral flywheel belthousing, There is ne parlition between the transmission gear train and the final dive, as both are lubricated by the common hypoid gear oil supply in the transaxe case. Five-Speed Manual Transmission ‘The transmission gears are of the constant mesh type with balk nng synchronizer. Each gear (1st through Sth) is actually ‘a mating pair of gears, and constart-mesh simply moans tho ‘mating gears are always meshing. When shifting gears, syn- ‘’chronizers cause the moving parts to rotate at the same speed before engaging. This prevents damage to the gears, min rmizes wear, and eases shifting. The 3rd, 4th, and Sth gear synchronizers are on the mainshalt; the tel and 2nd gear synchronizers are on the pinion shaft. Gear selection is made through the gearshit lever in the passenger compartment, whic linked to the transmission by the gearshif linkage. Final Drive ‘The ring and pinion gearset consists of two helica-cut gears (curved teeth), designed for quiat running. The driven gear, oF ring gear, is mounted on the cifferentia! Rousing. The driving gear, oF pinion, is an integral part of the pinion shaft. The cifferentia gearset, which consists of two diforental sidegears. 2nd gear 1st goar Ua eyMANUAL TRANSMISSION AND CLUTCH 8-5. and two diflerential pinions, allows the front wheels to turn at Table a. Manual Transaxle Specifications speeds, as is necessary when making turn (the out rust travel farther than the inside wheel in the same amount of time}, ‘Transmission a0 020 20 1.3 Identification Codes and Specifications Gear Ratios ansaxles are identtiodby a serios of characters stamped | 1#* Gear sas on the battom of the bellhousing, as shown in Fig. 1-2. Atwo or oiohbal ca three character code identifies the transax's type, followed by | 3¢d Gear Ath Gear ‘5th Gear series of numbers identifying the date of manufacture, A man ansmission type nurnber is located on the driver's side of se naar the diive flange as shown in Fig. 7 Final Drive Ratio 2. MAINTENANCE c clutch pedal freoplay ata preserbed mileage, ex ‘cept on models with self-adjusting clutch cable, isthe only re quirad maintenance procedure. The transaxle is designed ta bo lubricatedtor ts operationallite, so checking and correcting the transaxis oil level's not necessary uniess the transaxle is leaking or has been repaired. Checking pedal freeplay and ‘checking transaxle oil evel are deseribed in LUBRICATION. AND MAINTENANCE, 3. TROUBLESHOOTING his troubleshooting section applies to problems atfecting 1nd dite of manufaciw® the correct functioning of the transaxlo—ineluding the gear a ansmissions, Fx shat mechanism, the gear train, and the final drive—as well as : ? theciuteh, The source of mosttransaxle problems is apparent fromthe symptoms. Fot example, difficulty in engaging a gear, shud- dering when releasing the clutch, or a vague shiting mecha: ism are all transaxle probiems, Other symptoms, such as power loss or noises framthe frontend, are less specie, Pow- er loss may be due te an engine problem, or fo a slipping clutch. Noises may be the resut ofa failure in the goar train, worn constant velocity nts, or abad whee! bearing, What ap pears to be a transmission oil leak may be engine ail leaking from a faulty rear crankshaft oil seal, especially if the leak is. near the bottom of the transaxle bellhousing. Sa ENGINE tor information on crankshaft oil seals. S2e SUSPENSION AND STEERING for information on constant velocity joints and wheel bearings, 3.1 Basic Troubleshooting Principles imcer (020) on fve-2peed man Transaxle problems fall into two categories: those that can be fixed by external adlustments, and those which raquire re ‘moval and disassembly of the transaxie. Problems which at first appear to be caused by interaalfaulte, such as gear shit ing dificity or noisy operation, may be correctable with exter nal adhustments,8-6 | MANUAL TRANSMISSION AND CLUTCH ‘Bogin any transawe troubleshooting with a thorough visual inspection, both in the engine compartment and trom Beneath Check all parts of the gearshift mechanism for wear which ‘might cause misalignment and shitting difficulty. Look for wet spots which may indicate oil leaks. Low lubricant level may 62 the cause of hard shiting or noise. Accurate pinpointing of ieaks may require that the suspected area be cleaned and reinspected, To avoid removing the transaxde unnecessatiy, check and adjust the gearshit mechanism and correct leaks and oil level before acting on suspected intemal problems. The gearshit mechanism is coverodin 4. Shift Mechanism. replacement of, (0) seals is covered in 6.2 Transaxle Oil Seals. Checking and ‘correcting cil evel is coverod in LUBRICATION AND MAINTE NANCE, NOTE — ft nat necassary to routinely check the tans lle oi ve! unless lank i suspactec. ‘As with: most ather troubleshooting, logical analysis af the observed symptoms is the key to isolating and identiying transaxle problems. A road test is an important step when troubleshooting the transaxle. Determining whether the prob. loan is present in all gears, only during acceleration, when the Clutch is engaged, or in some other specil conditions may help isolate the source of the problem, Table b lists manual transmission, final drive, and clutch symptoms, their probable causes, and recommended correc: tive actions. The numbers in bold type in the corrective action ‘column refer to numbered headings in this section where the suggested repairs are described, ‘Table b. Manual Transaxle Troubleshooting ‘Symptom Probable cause 1. Bitour or noicy ‘2 Glutch not tly leasing siting Cui cise bindeig on transission rmainahatt © Woin or misacjusted gearshit iokage 4. Insuticent gear of T | | ©, Worn or damaged intemal a | : ponents 2. Transaxle nosy stficient oar ol . Wor oe damaged intemal ransande components 23. Gnnting noise when shiing (tor covess0 90203) 1. Bxcosewe ice peed Wor or damaged interna Iransmission eomgonerts 4. Tansmsion fi 19 engage 3 gear oF sumps out of gear 1a. Wort or misacjustod gearshift inkage Wor or darnagad intemal ‘ransmission components |. Cuich friction surtaces worn or burt |B. Cen not ty engaging Clic cise, presaure plae or yhoo 22 ol soko 5. Poor aeoseraton, luteh sipping on hs or whe a. Binding cach cable haters whon the pedals released |, ulen dice binding on transmission mainshaft {© Contamnated or gtazod! (overheated) Sateh tring | &. Fautty engine mount — | Corrective action '. Adjust cluch pedal eeplay 5.4 'b Romove transaxle and inspect splines of clutch dsc and largmssion mainshar. Lubricate splines. f necessary. replace ‘utch dee, 6. 6. Adjust shit mochanism and, if necessary, enlace worn parts. 4 | andes | 4. Check for vansmnission of leaks. Check and correct goar ot fove | i(newded. Sow LUBRICATION AND MAINTENANCE 8. Remove and repair transmission. 6:3 2. Check for ansnission of oaks Check ard correct gear ol level | iineceded, Seo LUBRICATION AND MAINTENANCE |b. Remove and repair vansine. Especialy checking the dlterenta, oars. 6.3 ‘8 Adjust idle Speed. Soe FUEL SYSTEM 'b Flomove and repair tarsmission. Espacialy checking the synchronizer ofthe noisy guar. 63 a. Adjust shut mechanism and, necessary, pace worn parts 4.4 end »b. Hormove and copaievarsmision, 6.3 |. Inspect clutch companents and replace fauty parts. §2 Adjust catch pedal rowplay 5.1 «5 Inspect clutch componenis. I necassary, clean pressure pate and Rywhee veplace cuten dee. 82 42. Inspect te clutch cable. Replace the cable is saveely bent or cotherwrge fauty. 5.1 |b. Remove ransawe and inspect splines of clutch ise anc luansrnission mainshan. Lubrcate spenes. H necessary, replace chien cis. |e Insect etutch components and replace fauly parts 5.2 4. inspect anc, necessary, replace broken engine mounts: See ENGINE3.2 Diagnostic Tests Most internat transaxle problems cannot be accurately d agnosed uniess the unit is removed and disassembled: how- ever, a quick test can be used to determine whether the clutch is pettorrning satistactoriy or sipping To quick-checkelutch performance, star the engine andset the parking brake. Depress the clutch pedal and piace the gearshift lever in ard or 4th gear, then slightly accelorate the engine and slowly release the clutch pedal, The engine should immediately stall, indicating thatthe cluich s engaging proper- lyand wal not slip enough ‘allow the engine to continue to tun. Ifthe engine stalls siowly, or does not stall at al, the clutchis probably faulty. Adjust the clutch pedal freeplay, as deseribed in 5.1 Cluteh Cable, andrepeatthetest, the clutehisstil slip- ping, the transaxle will have to be removed to make further re pairs te the clutch. Bal pots MANUAL TRANSMISSION AND CLUTCH 8-7 4. SHIFT MECHANISM Tho transverse mounting of the transaxle in vehicles cov- fered by this manual requires a relatively complex mechanisra of shatts and levers to transmit the movements ofthe gearshift lever to the transmission for gear changes. For any shitting problems, the gearshift mechanism should be inspected for wear and misalignment which might affect smooth or accurate shifting. Fig. 4-1 shows the arrangement of the shift snecha- nism and is directions of movernent. 4.1 Disassembling, Assembling, and Adjusting Shift Mechanism Fig. 4-2 is an exploded view of the shit mechanism used with five-speed manualtransmissions, which can be used asa. guide for disassembling and assembling the linkage, to re place any worn bushings, or when removing the transaxle. When removing the selector rods, use a screwdriver to press back the clips on the plastic rod ends before pulling them off cf the ball pins on the levers. When assembling, femove any white grease from the linkage and lubricate allcints and pivot points with molybdenum disulfide grease (Volkswagen part no. 6.000802). Also, make surethat he connecting links instalisd totha eelector shaft lever and relay lever as shown in Fig, 4-3 Main sti vos8-8 | MANUAL TRANSMISSION AND CLUTCH | Selector shalt detent phanger (early models) Bolt later mols) == Sih goar detont plunger (ealy mod oniy) Rey ever Fig. 42 20 Nm 1511) To adjust: Shift Mechanism Adjustment ‘The position of the selector lever on the shit rods the only 5 adjustment that can be made to tne shift mechanism, Before _agjusting the shif rod to correct shifing dificutios, frst check for any worn or broken parts of the shift mechanisi. Park the car on alevol surace, Set the parking brake and place the transmission in neutral, {Loosen the lock nut on the shift rad camp bolt, shown in Fig. 4-4, so thatthe shift rod moves freely in the selector \Workingunderthecas.removethe cover fromthe weather seal boot atthe base of the gearshift lever, of, nero 1s no cover, remove the boot and slice it forward on the shift 10d ‘Move the gearshift lever so that tis postioned in relation ‘othe lockout plate as shown in Fig. 4.5. Thon tighten the clamp locknut to 20 Nim (15 ft. 1b) Check that al the gears engage smoothly and easly. Reinstall the gearshift weatherseal boot and coverMANUAL TRANSMISSION AND CLUTCH 8-9 Fg. 44, Removing and Installing Shift Lever and Shift Rod Fig. 4.6 fe an exploded vis hit lever and related it ever, the m in Shift Mechanism Adjustment,8-10 MANUAL TRANSMISSION AND CLUTCH To remove and install the shit knob, Femove the boot by detaching tat the battom and puling it off ever the gearshift | xing beneath the car, remove the cover from the 1e'seal boot at the bottom of the shift lever, or, # tere 1s no cover, detach the boot and slide it forward on the shift rod, holds the gearshift lever to the 4. Working in the passenger compartment, re mounting bolts for the shift lever b and withsraw the shit lever and ove the raring assembly "9. Installation reverse of removal. The beating is only available as a complete ieplacement part, but it can be disassembled as shown in Fig, 4-7 for cleaning and greasing. Remove any ald grease from the joints and pivol points, and lubricate them with molybdenum disulfide grease (Volkswagen part no, @ 000 602). in the bearing assembly az shawn in Fig, 4-8, and ‘arque the bots to 8.5 Nov (74 in, .). Terque the bolt ‘and shit lever to 7/Nm (61 in.) Fig. 47. « 5. CLUTCH Except for replacement or agjustment of the clutch cable, any repairs to the clutch require that the transaxle be removed from the car. The flywheel and the clutch assembly remain bolted to the crankshaft when the transaxle is Separated from the engine, The clutch release bearing and its related parts are located at the opposite end of the transaxle, and operate the lutch by means ofa pushrod running through the center of he mmainshaft. Fig. 5.1 is an exploded view of the cluich compo: nents, 5.1 Clutch Cable “Two types of clutch cables are used on the vehicles covered by this manual, The more conventional, manually-adjusted cable neods periodic adjustmont to compensate forthe wear of the clutch friction material. For mieage intervals, see LUBRE CATION AND MAINTENANCE. Some models are equipped with a self-adjusting clutch cabie. It has a builtin mechanism which automatically com: pensates for wear, adjusting every time the clutch pecial is actuatod. The self-adjusting cable can be identified by the ‘uidber boot atop the clutch cable sleeve on the transawie end of tho cable, as shown in Fig. 5-2. The two cables are not interchangeable. Flemoval and installation ofthe clutch cable can be aecom- plished without any special tools. Replacement seltadjusting cables come with a holding strap that relieves the spring tension and allows easy instalation. If the cable does not have the atrap attached, a helper may be needed during installation.MANUAL TRANSMISSION AND CLUTCH 8-14 Fig. 5-1, Ea soch wew ot tytn ad cute8-12 MANUAL TRANSMISSION AND CLUTCH ‘To replace clutch cable: 1. On manually adjusted cables, loosen the adjusting sleeve lacknut and turn the sleeve clockwise unti the cable's tonsion is relieved. Remove the securing parts ‘fom the cable end beneath the clutch release lever and pul the cable end fram the lever. On sottadjusting clutch cables, depress the clutch pedal several times. Compress the spring (under the ruber boot) and have a helper remove the securing parts from beneath the cluch release lever. Pullthe cable end trom the lever. ‘cauTioN—~ ‘Do not apen the automatic adjustment macha riser. ifthe adjustment mechanism 18 opened, the cable assembiy wil need be voplaced. 3. Unhook the cable end from the top of the clutch pedal and pul the cable through the firewall from the engine compartment side. 4. Install the clutch cable. Lubricate both ends with ru purpose grease, then insertthe clutch cable end through {he firewall grommet and hook the cable onto the clutch pedal Position the rubber washer and the -ubber grommet as, shown in Fig, 5-3. Fig. 5-3. ausver wash vaste Ys bh " X aubbor grommet comecty esa, Fi ‘seh ap 2 parade lo saloon shat cove ‘cauTION—— 7 1988 and 1986 maces I's especialy im- portant that the rubber parts are installed cor ‘lly not. the transeile vant which pro: fected by the washer may become clogged, ‘anc cause ol feakage past the seats, For more Information 900 6.2 Transaxle Oil Seats, 6. Ifreinstafing a used self-adjusting cable, compress the ‘spring (beneath the rubber boot. 7. Insert the cable end through the rubber grommet and the release lever. Attach the securing parts to the end of the cabio, 8. On setf-adiusting cables, adjust clutch pedal freeplay by :exnoving the spring retaining strap or relieving the spring tension, and then operating the clutch pedal several times, To adjust (except self-adjusting clutch cable): 1, Operate the clutch pedal several times. Loosen the oa ble lock, 2. Raise the clutch release lever by hand until resistary 1s fel. 5. Adjust fteeplay by turning the adjusting disc untit the learance between the adjusting disc and the transaxle housing is 12.003 mm (.472:.012 in). See Fig, 5-4 Sloove eu a lect Adjusting dae 4 jo grommet how Rubber: washer Fig, 64, fucing on i igokatch lease hand. Adjusting gauge shown is Voksen spe 043 fordor no, TUS 143 000 30 troapty mph ‘a ool m0, Zap. Tighten the cable locknut. Freeplay at the cluteh re ase lever should now be 6.0.0.3 mm (,296+.072 in) “Torque the locknut to 4 to 6 Nm (36 to 48 int)MANUAL TRANSMISSION AND CLUTCH 5.2 Removing and Installing Clutch The transaxle must be removed from the engine to gain ‘access tothe clutch, See 6.3 Removing and installing Trans- axle. itis normally recommended that the pressure plate be Teplaced when a new clutch disc is installed, if the clutch pressure plate is removed from the crankshatt, new mounting bolts should be used to reinstall The fywheel should be carefully inspected when replacing the clutch. Replacing the clutch disc without replacing other worn components may accelerate clutch dise wear. {An inexpensive alignment too! is used to install and canter the clutch disc. Use ofthis too! ots equivalent will greatly aid the installation of the transaxle. For JH engines, use Vokswa- {gen special tool no. VW $47 (order no. TO 547 000 30 ZEL) ‘or PL. (16-valve) engines, use Volkswagen special too! no. 3178 forder no, TOS 178 000 30 ZEL). ‘Some lubrication is recommended when reassembling the clutch. To avoid accelerated falure of the new parts, use only the Volkswagen recommended lubricants. signs of oi! are present at the bottom af the transaxle, carefuly inspect the rear Crankshaft oll seal while the clutch is remaved. A fauity ol seal should be replaced. To replace clutch: |. Remove the transaxle from the engine as described in 6.3 Removing and Installing Transaxle Remove the fiywheel, clutch disc, and release plate. A holding fixture, Volkswagen special toot number WW 555 {order no. TVO 558 000 13 ZEL}, is shown in Fig. 55, Loosen the flywheel mounting batts evenly, one-quarter turn ata time, until the clutch pressure i relieved, Re- ‘move the flywhoel and the clutch dsc, 3. Use a screwckiver to pry out the retaining ring for the clutch release plate. 8-13 WARNING —— The rotaining rng 18 a spring wich wil be 1 sed with Some force. To ave iy, ake onto i trmiy wnve png & loose 4. Remove the six center mounting bolts and ramove the Clutch pressure plate trom the erankshatt. Use of the holding fixture is illustrated in Fig. 5:6 Fig. 5-6 Hoding fit.ze used to somove oluch a ‘To inspect and install 1. Inspect the clutch pressure plate. Check the release lo vals for bending of misalignment, Using 4 straightedge as shawn in Fig. 5-7, check that the mating surface does not taper inward more than 0.3 mm (012 in.) that na rivets are loose. Caretully inspect n sutace tor cracks, scoring, discoloration due to heat o oil contamination, oF other damage. A cluteh proseurs plate showing any of these signs of ddarnage should be replaced, the tnt Fig. 57. Pressure pale bor feauge ever 0:30 mm (0 late anc taightedge on bale should be replaces8-14 MANUAL TRANSMISSION AND CLUTCH 2. ivan the flywheet trction surface and inspect it for wear, cracks, and grooves. Chack fr loose or worn dowel pins Replace a flywhee! with ary of these faut, heck the thickness, runout, and general condition of utoh disc. See Fig. 58. I runout exceeds 0.40 mm 016 in), oF there is Bry evigence of contamination by oil, the dise should be replaced {eh discis arolaively low-cost part which omnonly wears ou and requites replacers Many ely sala 4, Inspect the splin tise and the transmis on input shaft. Check that the clutch dise is free to slide on the shat. ifthe clutch dise isin any way unser: viceable, it should be replaced. Clean all traces of grease irom the shatt and clutch splines 5, Position the clutch pressure plate on the erankshatt Using new bolts, position the washer and thread the ts inte place. The hoiding fixture shown earlier in Fig 5:6 can be used to hold the pressure plate. Torque the bolts to 30 Nm (22 ft. tb.) plus 1/4 tue, ‘CAUTION — Always use neve prossure plate mounting bots ‘und. Once forged they are sofarmed and should not bo reused 6, Place the clutch release plate in position and install the ‘taining ring. Lightly lubricate the contact surtace of ho plato and the center seat for the clutch pushtod wth lithium grease. Align the ends of the retaining ring as shown in Fig, & 7. Lightly lubricate the transmission mainshalt and the clutch splines using molybdenum disutide grease, Volkswagen part no, G 000 602, then place the clutch dice inside the flywheel. Use ony nmonded maiyscsonu ais! ise grease on the spines. Othenvise the clutch may bind on the inp shaft ac case hard shifting, Othor Mbreants may contaminate the NOTE — “The projecting part of the clutch hub faces the Aiywheal aoay from the angie, 8. Instal the flywheel, Position the tlywheel on the dowel pins and start the mounting bolts in their holes, Leave the bolts loose enough so that the clutch disc can still caution — The tao guide pins in te lywhee! must aign wits the carespeneing hoes i to elitch pres sito plate, or the pressure plato will be dan aged. during instalation. Do not mistake Balancing holes fr guide pin holes, 9. Center the clutch dise. The Volkewagen 5 Used to accurately center the disc is shown in Tighten the flywheel mounting bots evenly until the clutch dise is firmly held in place. 10. Remove the centering toot, used, and torque the boits to20 Nm (151 1b.) in the sequence shown in Fig, 511 smentfywhecs for gasoline onginos have no tening mak. They aro marked only with 120° TDC matk, Bofore instaling, make ating mart as shown in Fig. 5-12