How to install a clutch? - Jetta Volkswagen Cars & Trucks

Internal leaks in a hydraulic clutch system can be caused by several factors, including:

Worn or damaged seals: If the seals in the clutch system are worn or damaged, fluid can leak past them and cause the clutch to malfunction.

Damaged clutch master cylinder: If the master cylinder is damaged, it may allow fluid to escape, causing the clutch to lose pressure and function poorly.

Air in the system: If air has entered the hydraulic clutch system, it can cause leaks and reduce the effectiveness of the clutch.

Improper installation: If the clutch components were not installed properly, this can lead to internal leaks and reduce the clutch's performance.

Clutch hose damage: If the clutch hose is damaged, this can also cause fluid to leak and reduce the clutch's performance.

If you have recently replaced the clutch components and are still experiencing leaks, I recommend checking all components for damage or proper installation. If necessary, consider taking the vehicle to a mechanic for further inspection and repair.

check clutch installment procedure could be the problem how it was installed.

the problem may have been in the damper spring setup in the clutch plate
it the clutch plate was a standard plate , it would have had 4 damper coil springs but the last plate fitted may have been a heavy duty plate that would have had 5 or 6 damper springs
if the springs are of insufficient tension then there is a grabbing action during clutch engagement but with more springs and different tensions that is overcome and the action is a smooth clutch application
manufacturers that have design faults quickly change the design as clutch shops are fussy when it comes to rework so I would think that it is not the clutch but an incorrect plate for the application

Hello, Who installed the clutch"? Were there a new pressure plate installed? Were there a new throw out bearing installed. Does this 1991 Peugeot 405 have hydraulic or mechanical clutch linkage?
There a couple of reason why the Peugeot wont move and engine is running and the transmission is in gear.

1.. Pressure plate is installed backwards.--Remove transmission and reinstall pressure plate in the correct orientation to the clutch. There is two ways to install it, but one way correctly.

2. Adjustment for the clutch linkage from the pedal in the driver compartment is adjusted to tight and not releasing the clutch to where the clutch pressure is on the pressure plate.



I hope this helps. GB....stewbison

Clutch and Clutch Field Coil Printable View (235 KB)
Special Tool(s) 2-Jaw Puller
205-D026 (D80L-1002-L) or equivalent Installer, A/C Compressor Coil
412-065 (T89P-19623-EH) Holding Fixture, Compressor Clutch (3.8L vehicles)
412-098 (T94P-19703-AH) Holding Fixture, Compressor Clutch (4.6L vehicles)
412-103 (T95L-19703-AH) Remover, Differential Bearing
205-116 (T77F-4220-B1) Installer, A/C Compressor Field Coil
412-078 (T91L-19623-CH) Remover, A/C Compressor Field Coil
412-067 (T89P-19623-FH) Removal

1. Remove the A/C compressor (19703). For additional information, refer to Air Conditioning (A/C) Compressor - 3.8L or Air Conditioning (A/C) Compressor - 4.6L in this section.

1. Remove the bolt.
   1. Hold the A/C disc and hub assembly (19D786) with the special tool.
   1. Remove the bolt.

1. Remove the A/C disc and hub assembly and the A/C clutch hub spacer (19D648).
   1. Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft.
   1. Lift the A/C disc and hub assembly and the A/C clutch hub spacer from the compressor shaft.

1. Remove the pulley snap ring.

1. Remove the A/C clutch pulley (2E884).

1. CAUTION: Do not use air tools. The A/C clutch field coil (19D798) can be easily damaged.
   Remove the A/C clutch field coil.
   1. Note the location of the A/C clutch field coil electrical connector.
   1. Install the special tool on the nose opening of the A/C compressor.
   1. Install the special tool.
   1. Remove the A/C clutch field coil.

Installation

1. NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed.
   Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage.
   • Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat.
   • Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth.
   • Inspect for roughness in the A/C compressor pulley bearing.

1. Clean the A/C disc and field coil and pulley mounting surfaces.

1. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
   Install the A/C clutch field coil.
   1. Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned.
   1. Using the special tools, install the A/C field coil.

1. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation.
   Install the A/C clutch pulley.

1. Install the pulley snap ring with the bevel side out.

1. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening.

1. Install the A/C clutch.

1. Using the special tool, install the A/C disc and hub assembly retaining bolt.

1. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.

1. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor - 3.8L or Air Conditioning (A/C) Compressor - 4.6L in this section.

hope this helps

OK, loss of cooling fan speed. I will say this is plausible. I'll take your word for it (sometimes my online resource is not complete).

Cooling Fan & Shroud Removal & Installation To Remove:

1. Drain the coolant from the engine.
2. Remove the air cleaner assembly from the engine compartment.
3. Remove the air resonator assembly from the engine.
4. Remove the inlet radiator hose from the radiator.
5. Detach the transmission oil cooler lines from the fan shroud.
6. Disconnect the fan clutch connector. Fan clutch removal and installation
   
   
7. Use a J 46406 fan clutch remover and installer to remove the fan clutch from the water pump.
8. Remove the upper mounting bolts from the fan shroud.
9. Remove the fan shroud from the radiator by lifting the shroud and pushing inward.

To Install:

1. Attach shroud to the radiator. Torque the bolts to 21 ft-lb (28 Nm).
2. Use a J 46406 fan clutch remover and installer to install the fan clutch onto the water pump.
3. Connect the fan clutch connector.
4. Attach the transmission oil cooler lines to the fan shroud.
5. Install the inlet radiator hose to the radiator.
6. Install the air resonator assembly onto the engine.
7. Install the air cleaner assembly into the engine compartment.
8. Refill the engine with coolant.

The clutch is not adjustable,it is a fluid clutch.It has to be a leak,or the slave cylinder,and,or, the master cylinder are bad,It does not have to be leaking to be bad,but it is one of the two.Rate please,thank you.

In the Toyota Pick-ups/Land Cruiser/4Runner 1989-1996 (free register) can find several graphics about this.

Driven Disc and Pressure Plate - REMOVAL & INSTALLATION

(see Figures 1 through 27).




CAUTION The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid. Never clean clutch surfaces with compressed air.

1. Remove the transmission.

1. Matchmark the clutch cover (pressure plate) and flywheel, indicating their relationship.

1. Loosen the clutch cover-to-flywheel retaining bolts one turn at a time in a crisscross pattern. The pressure on the clutch disc must be released GRADUALLY.

1. Remove the clutch cover-to-flywheel bolts. Remove the clutch cover and the clutch disc.

1. If the clutch throwout bearing is to be replaced, do so at this time as follows:

1. Remove the bearing retaining clip(s) and remove the bearing and hub.
2. Remove the release fork and the boot.
3. The bearing is press fit to the hub. Turn the bearing by hand while placing it under some pressure; check for freedom of motion and lack of grinding or resistance. The bearing is permanently lubricated and cannot be disassembled or greased.
4. Clean all parts; lightly grease the input shaft splines and all of the contact points.
5. Install the bearing/hub assembly, fork, boot, and retaining clip(s) in their original locations.

1. Inspect the flywheel surface for cracks, heat scoring (blue marks), and warpage. If oil is present on the flywheel surface, this indicates that either the engine rear oil seal or the transmission front oil seal is leaking. If necessary, replace the seal(s). If in doubt concerning the condition of the flywheel, consult an automotive machine shop.

1. Before installing any new parts, make sure that they are clean. During installation, do not get grease or oil on any of the components, as this will shorten clutch life considerably. Grease or fingerprints may be cleaned with an evaporative cleaner such as the type used on brake linings.

To install:

1. Position the clutch disc against the flywheel. The long side of the splined section faces the flywheel.
2. Install the clutch cover over the disc and install the bolts loosely. Align the matchmarks made. If a new or rebuilt clutch cover assembly is installed, use the matchmark on the old cover assembly as a reference.
   

Whenever the clutch disc is replaced, replacement of the pressure plate (clutch cover) and release bearing is highly recommended.

1. Align the clutch disc with the flywheel using a clutch aligning tool. These handy tools are available in many auto parts stores at a reasonable price. Do NOT attempt to align the clutch disc by eye; use an alignment tool.

1. With the clutch aligning tool installed, tighten the clutch cover bolts gradually in a star pattern, as is done with lug nuts. Final tighten the bolts to 14 ft. lbs. (19 Nm).
2. Apply molybdenum disulfide grease or multi-purpose grease to the release fork contact points, the pivot and the clutch disc splines. Install the boot, fork, and bearing on the transmission input shaft.
3. Install the transmission.

Hope helped.

REMOVAL:

1. Lift clutch pedal to uppermost position to disengage clutch and brake pedal pivot shaft.
2. Push clutch and brake pedal pivot shaft forward and unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward.
3. Raise and support vehicle.
4. Remove clutch release lever dust shield.
5. Disconnect clutch release lever cable from clutch release shaft.
6. Remove retaining clip, then clutch release lever cable from flywheel housing.
7. Remove starter motor from flywheel housing, then engine rear plate to front lower flywheel housing bolts.
8. Remove transmission.
9. Remove flywheel housing back just far enough to clear clutch pressure plate, then remove housing.
10. Remove clutch release shaft from flywheel housing by pulling it through window in flywheel housing until retainer spring disengages from pivot.
11. Remove clutch release hub and bearing from clutch release shaft.
12. Loosen six clutch pressure plate bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate. If same clutch pressure plate is to be installed, mark plate and flywheel so pressure plate can be installed in its original position.
13. Remove clutch pressure plate and clutch disc from flywheel.

INSTALLATION:

1. Position clutch disc and pressure plate assembly on flywheel, noting following:
   1. Three flywheel housing to block dowels on flywheel must be properly aligned with clutch pressure plate.
   2. Bent, damaged or missing flywheel housing to block dowels must be replaced.
   3. tart clutch pressure plate bolts but do not tighten.
   4. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.
   5. Align clutch disc using suitable alignment tool inserted in pilot bearing.
   6. To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight, then tighten to specifications.
   
   
2. Install transmission to flywheel housing.
3. Install engine rear plate to flywheel front lower housing bolts, then connect clutch release cable to flywheel housing and connect retaining clip.
4. Connect clutch release lever cable to clutch release shaft, then install clutch release lever dust shield.
5. Install starter motor.
6. Lower vehicle, then install clutch release lever cable as follows:
   1. Lift clutch pedal to disengage clutch and brake pedal pivot shaft.
   2. Push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft.
   
   
7. Cycle clutch pedal several times to adjust clutch release lever cable

Hope this helps. Best of luck to you!
Greg

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
   
2. Disconnect the negative battery cable.
   
3. Remove the transaxle.
   
4. Gradually loosen the clutch pressure plate bolts, in a crisscross pattern. Support the pressure plate and remove the bolts. Remove the pressure plate and clutch disc.
   
5. Inspect the pilot bearing. If it is worn or damaged and does not turn easily by hand, remove it using a puller/slide hammer.
   
6. Check the flywheel surface for scoring, cracks or burning and machine or replace, as necessary.
   
7. Install a flywheel holder to keep the flywheel from turning. Loosen the flywheel bolts evenly and gradually in a crisscross pattern. Remove the flywheel.
   
8. Inspect the clutch release bearing for wear. Replace it if it sticks or does not turn easily.
   
9. Inspect the release fork for wear or damage and replace as necessary.
   

To install: Structural view of the hydraulic clutch system
Exploded view of the clutch assembly
Click to Enlarge Flywheel tightening sequence
Pressure plate tightening sequence

1. Lubricate the release fork fingers and pivot with molybdenum grease and install in the release fork boot.
   
2. Install the clutch release bearing on the release fork.
   
3. Install a new pilot bearing in the flywheel, if removed.
   
4. Be sure the flywheel mounting surface and the crankshaft or eccentric shaft mounting surfaces are clean. Remove any old sealant from the flywheel bolt hole threads and the flywheel bolts.
   
5. Install the flywheel.
   
6. Apply sealant to the flywheel bolt threads and install them hand-tight. Install the flywheel holding tool. Tighten the bolts, in a crisscross pattern, to 71–76 ft. lbs. (96–103 Nm).
   
7. Apply a small amount of molybdenum grease to the clutch disc splines and install the clutch disc on the flywheel, spring side toward the transaxle. Install a suitable alignment tool in the pilot bearing to position the clutch disc.
   
8. Install the clutch pressure plate, aligning the dowel holes with the flywheel dowels.
   
9. Install the pressure plate bolts and gradually tighten, in a crisscross pattern to 20 ft. lbs. (26 Nm). Remove the alignment tool.
   
10. Install the transaxle.