Rabbit needs a new clutch.

[tyb525]

I believe the clutch is on it's way out (as in, if I drove it again, I'd get stranded). I tried adjusting the clutch, it has about 3/4"-1" of free play like Bentley calls for, but no luck. It's bad enough that flooring it in 4th going 55 the engine revs up like I pressed in the clutch.

So unless I'm missing something, looks like I need a new clutch. What size clutch does an '81 1.6NA with the GP 4 speed use? 200mm? And what else is good to replace while I'm in there.

The other option is finding a 5 speed, but I'm sure that'll be a little more costly.

I knew I should've replaced it when I have the engine apart last fall...

[RabbitJockey]

sounds like u need a clutch!  u can find 5 speeds pretty cheap, most junkyards are packed with mk3's, then all you'll need to find is the top side motor mount and mk1 5 speed linkage.  or u can just keep it simple and simply change the clutch, rear main seal, and all the seals.bushings in the bell housing of the trans.

[CRSMP5]

i see people say cheap trannies... wish they existed.. mk3 most all have rev gear issues.. $400 in parts.. finding old no value 4 speed for those parts good though.. you have...

but in no way will i install a yard 020 from a mk3 with out a tear down planned..

now if you do the 5speed make sure the disk fits... mk3 has bigger splines...

[burn_your_money]

I thought you couldn't use the mk3 trannies in a mk1 because the diff doesn't have those studs for the rear mount?

[RabbitJockey]

Tyler it's the other away around, the earlier mk1 trans didn't have the spots to mount a mk2/3 mount.  Some mk3 trans do have the holes drilled and tapped but the boss is there.  And yeah mk3 tranny would not be my first pic but they're definitely available.  I see 020 sell cheap all the time on Craigslist and vortex

[burn_your_money]

Right, thank you. I ran into that when I tried to put a 4A in my Mk2.

[wolf_walker]

Speaking of which, anyone else less than thrilled with Sachs clutches lately? 
Mine is noisy at idle and the one that came out wasn't that old and the springs
had fallen out of the center of the friction disk, which is the 2nd time I've seen that
on a stock NA diesel now, both Sachs.  The Porsche one's still seem OK the last
few years, but they aren't spring centered.

[RabbitJockey]

Speaking of which, anyone else less than thrilled with Sachs clutches lately? 
Mine is noisy at idle and the one that came out wasn't that old and the springs
had fallen out of the center of the friction disk, which is the 2nd time I've seen that
on a stock NA diesel now, both Sachs.  The Porsche one's still seem OK the last
few years, but they aren't spring centered.

I have heard alot of people talking about poor quality for years especially on mildly built 16vs that could rip the straps off the pressure plate

[tyb525]

Yikes, already ordered a Sachs kit. Guess we'll see, wasn't too expensive....

BTW, can I reuse the bolts? Most places say no, but I think I saw somewhere the bolts on older cars like my '81 weren't TTY therefore they can be reused? If not who sells them? I see them individually on Ebay, but I'd like to buy them as a set. Parts Place has one for $50 (yikes!).

[Gizmoman]

Yikes, already ordered a Sachs kit. Guess we'll see, wasn't too expensive....

BTW, can I reuse the bolts? Most places say no, but I think I saw somewhere the bolts on older cars like my '81 weren't TTY therefore they can be reused? If not who sells them? I see them individually on Ebay, but I'd like to buy them as a set. Parts Place has one for $50 (yikes!).

Try McMaster Carr - you'll have em in one day and for a lot less than 50 buck for the set

[theman53]

idparts.com or autohausaz.com is what I use.

[CRSMP5]

no reason to replace the bolts... UNLESS you move from stock 200mm clutch to 210mm.. then you need bolts as they use 9 vs 6..

yea mk1 take them all.. may have to play with axle flanges aka put 90mm ones on.. or mod spindles for 100mm rocco axles (mk2/mk3 too long).. but flanges easy to swap but finding the spring loaded 90mm cups are not so easy anymore..

[monomer]

plate to motor bolts should be new.


flywheel bolts, well: used should be ok.



Just putting a bigger clutch in mine this weekend. I bought the kit from germanautoparts.com and the new gasser FW from rockauto (LUK brand) This is an area one shouldn't cheap out on, change the pushrod and it's seal, and check for a cracked finger also. You're there anyways; and last I checked theirs much more fun things to do than dropping a trans.

Change the rear main and input shaft seal also, an oil leak will ruin your new clutch right quick. The GAP kit comes with them. www.brokevw.com has the info for changing these.

[mystery3]

I had this- http://www.vwdiesel.net/forum/index.php?topic=25660.0 happen to two sachs clutches, the second looked even worse that this one. Look elsewhere, luk, spec, whatever. If you buy an expensive clutch kit I think your money will be saved by not having to r & r the transmission in 10k miles. Garbage.

[wolf_walker]

Yep, same deal. One in mine now is a year old or less. Hmm..

Sent from my SCH-I535 using Tapatalk 2