82 Rabbit Diesel Clutch Replacement Information

[jasons]

I have searched and searched and need to make sure I have everything I need to replace the clutch on my Rabbit. It's the 1.6L Diesel w/ 5-speed FN transmission.

I purchased the Sachs 200mm clutch kit.

Do I need to replace the pressure plate bolts?
Do I need to remove the flywheel? Seems like guys replace the flywheel when they do a clutch job on a TDI...don't know if it's the same on these old MK1s...

Any advise? Anything to watch out for?

Thanks guys,
-Jason

[air-cooled or diesel]

call back the co you bought clutch from and ask if new bolts are included, if not get a new set,,rear seal set, when installing rear seal grease seal(inner lips), you can use permatex or rtv for seal (outter), new flange gasket, i get new hardware nuts/bolts/washers; there are grease points for assembling a clutch, t-o bearing where it rides on pp some grease, some grease on input shaft splines and nose on input shaft, you may think of getting a new bearing for crank/trans input shaft. grease t-o shaft, maybe think of trans seals, input shaft seal being the most important, as you wont get a chance to open her up again. use just enough grease for job, wipe excess. new clutch cable? oil pan gasket to,, ?rear trans mount?, i apply red loctite to pp bolts. (clean before of course). ?new shift bushings? theres a few, fresh transaxle fluid.

[jasons]

Thank you for the info. I'll look at the clutch kit when I get home.
What's the flange gasket you're referring to?
I'll read about the crank bearing...sounds difficult.

I did purchase a few items to replace while the transmission is out...just didn't have time to post the parts earlier.
-Speedometer Cable
-Clutch Cable
-Clutch Cable Mounting Kit
-Shift Shaft Seal
-Front Main Shaft Seal
-Extension Housing Cover
-Rear Main Seal
-Throwout Bearing
-Throwout Bearing Shaft Seal
-Clutch Push Rod
-Clutch Push Rod Bushing
-Clutch Push Rod Seal
-Axle Shaft Seal x2
-Sachs Clutch Kit
-Motor & Transmission Mount Kit
-5-Speed Shift Linkage Repair Kit

My clutch is slipping something awful. It won't pull much of a hill without slipping. Should I be worried about the flywheel?

[air-cooled or diesel]

what fun! i like your list;
the flange is like the opposite side, seal carrier/flange; only this side is bigger, has seal in it, and has a gasket, +new oil pan gasket. i use new nut/bolts and stuff here; 1 thing i found about a lot of gaskets, the paper type after a few hours you have to come back and retighten, i find mine i come back the next morning and have to tighten some more, makes me feel better, and the is sealed off, so it can only help.
the bushing is what the input shaft goes into in crank, maybe clean it out and take a looksie in there and if it looks good grease nicely, i use hiquality syn stuff.

[air-cooled or diesel]

Should I be worried about the flywheel?

when you pull it apart you can decide if you want another flywheel; ive dont think ive ever had to replace one; but you can price a new1 or find used 1s. or take to shop and get it resurfaced

[TylerDurden]

Shopping list looks fine.

Beware, some members get confused between air-cooled machines and water cooled.

e.g. The watercooled 020 trannys don't have a pilot bushing in the crank end. The throwout bearing does not contact the pressure-plate.

Good tranny info here:
http://www.brokevw.com/index.htm

[jasons]

Have you all tried this material for the valve cover or oil pan?


Make leak-proof gaskets and return equipment to service immediately! Permatex’ premier instant gasket maker was designed as a replacement for conventional gaskets. This elastomeric “formed-in-place"material is more reliable and longer lasting than pre-cut gaskets. It is blowout resistant and protects against leaks and seepage caused by vibration and thermal expansion. Formulated to meet or exceed performance standards for long-term sealability, durability and handling, this material is used on OEM production lines and specified in their service parts programs. Temperature range -75°F to 450°F (-59°C to 232°C) continuous, 500°F (260°C) intermittent; resists ATF, coolant, oil and other shop fluids. Sensor-safe. Fleet-tested.

[air-cooled or diesel]

Beware, some members get confused between air-cooled machines and water cooled.

e.g. The watercooled 020 trannys don't have a pilot bushing in the crank end. The throwout bearing does not contact the pressure-plate.

do you have to be like that like the last time i had one of these trans' apart is in the '90s, a mk1 i had, and did 1 of my mk2s back then. havent had another open since, job isnt too difficult. most info is in shop manual. since last summer ive been doing some planning for my other mk2 to get a new clutch package,, soon me thinks

[Fatmobile]

I don't see a reason to use that sealant for valve cover or oil pan.
Because they make rubber gaskets that are reusable for both of those.
Normally for the Mk3 with the 2.0 gasser engine.
You can change the rear main seal without pulling the carrier, so the gasket isn't needed.
A large seal like that can be hard to get started. I wrote a post quite awhile back with a picture of my special tool so the seal lip doesn't catch on the edge and flip when installed. I hope you like sour cream.

[jasons]

Picked up the oil pan gasket this morning.

...something tells me the most enjoyable part of this was shopping around

[air-cooled or diesel]

Have you all tried this material for the valve cover or oil pan?

i ve seen that stuff; its ok; but that kind of sealant isnt the best thing; as it can come off in pieces in engine, is harder to clean up when you remove oil pan/valve cover etc. normally just a gasket is a better choice. stuff dries pretty quick and hard too.
i like your parts pic; reminds me of so many shipments ive get looking like that. being thorough helps ease the job and keeping it working longer,,

[Fatmobile]

Doesn't look like you got the rubber valve cover or oil pan gaskets.
Is the passenger side motor mount shaped like an upside down man or the heavy duty V shaped one?

[jasons]

Am I supposed to get rubber valve cover and oil pan gaskets? I went with what the old VW diesel shop owner suggested.

Let me know if I need to return these...

I bought this motor mount kit:
http://www.rsjparts.com/catalog/product ... 8a25fe9318

-Jason

[jasons]

Project starts tonight after work.

[Fatmobile]

I never use the cork valve cover gaskets anymore.
Or the fiber oil pan gaskets.
I would take them back and get the upgraded, reusable ones.
The Passenger side mount in the picture is what I call the upside down man.
It isn't the heavy duty mount.