differing clutch rod lengths?

[Quantum TD]

I'm pretty sure I know what your problem is. But first, I need a little history.

What do you know about this transmission? Did you buy it used, or did it come out of a car you actually drove?

I ask because, there can be an internal problem with the transmission that happened before you bought it.

This is a common problem, with a reasonably-priced solution. Here's how you figure out if my supposition is your problem. With the push-rod installed into the input shaft, hold the tip about flush with the end of the input shaft. Lift up on the clutch lever. The lever should be tilted DOWN about 5-10 degrees in relation to the horizontal ribs on the transmission casting. If it is HORIZONTAL or tilted UP from those ribbed lines, then you have an internal problem with the transmission.  

But, do not fret, this is an easy fix. You see, inside the 5th gear housing end-cover, there is a cast-metal lever. It looks like a cat's paw. It has a center hole which is splined to fit over the shaft of the clutch lever. The "cats paw" will often crack along the edge of the splined hole, and will SLIP on the clutch lever's shaft. In order to repair this, you will need to remove the clutch-lever and shaft from it's hole. You will need to pry off the GREEN inspection cover and remove the CENTER clip on the "cat's paw". Then, pull the clutch lever/shaft assembly out. You may need to try and reposition the cat's paw, as the shaft only goes on one way (two of the splines are moulded/welded together to form a double rib). Once it's out, you can go about replacing the paw, the clutch lever/shaft seal, the throw-out bearing and the green inspection cover. All of them are available new at your local dealer or CarQuest. I can fish out part numbers if you need em.

Here's an idea of where your lever should be in relation to the trans, and a pic of the cat's paw installed.

http://www.brokevw.com/releasearm.html

And a DIY on how to get to the cat's paw:

http://www.brokevw.com/TO.html


Also, the good thing about this, is you can replace the cat's paw even if the transmission is installed. Just tilt it down to clear the inner fender.

Let us know what you find out.

[motomike33y]

I was driving the car when a rod went thru the block, and the tranny was working good until that time.  The engine I'm mating it with is uncertain-purchased used from a dealer and put in a vehicle my brother ended up with.  bad wiring issues so car never ran-it turns over though and my jetta w/broke block does not.  I'll check it out when I try the other rod and plate.  I wondered about wear on the cat's paw, or whatever moves the clutch rod.  thanks.