Clutch question - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Clutch question by 1.9TD Caddy on 22 Nov, 2009 16:46
• Hi Guys, I replaced the clutch throwout bearing and installed a new clutch on the ACH transmission for my AAZ build.
  I am pretty sure I have hooked up everything correctly.
  The problem is with everything hooked up when I pull on the clutch release lever on the side of the tranny I dont feel any resistance. I t feels like the push rod is not pushing against the plate to release the clutch!!??
  I pulled the tranny back off the engine and verified that the push rod moves out (about an inch) when the lever is pulled up.
  Hooked it all back up...no resistance. What am I doing wrong?
• #1 by Vincent Waldon on 22 Nov, 2009 16:50
• Here's the exploded picture... did you miss something perhaps?
  
  
• #2 by 1.9TD Caddy on 22 Nov, 2009 17:08
• Thanks for the picture. I will pull it apart again and recheck in the morning. If I missed something it must be on the clutch end because with the tranny removed I can see the push rod move when I move the lever. Thanks again.
• #3 by Black Smokin' Diesel on 22 Nov, 2009 17:31
• That plate (#14) could be missing or have a hole in it where the pushrod should rest.
• #4 by Vincent Waldon on 22 Nov, 2009 18:43
• Actually that's an interesting question... what was the clutch doing before that caused you to replace it?
• #5 by 1.9TD Caddy on 23 Nov, 2009 07:01
• Well, the engine and tranny were bought used and in pieces. After I tore every thing down for the rebuild the clutch looked worn....so thats the reason for the replacement. I just got done taking the tranny off and double checking everything. All looks good however the disc fig 14 has a small ding in it caused by wear from the rod pushing on it over time.
  Any ideas will be much appreciated.
• #6 by dennis on 23 Nov, 2009 07:36
• Seen plate issues. Pressure plate not releasing? You can check that by trying to push the car while in gear. If seems like neutral I would think P.P. The rod can wear out too. Also there won't be any resistance on the lever untill the rod contacts the plate.
• #7 by Black Smokin' Diesel on 23 Nov, 2009 19:48
• Something else to check is the "finger" that pushes on the pushrod. It's moved by the lever the clutch cable pulls on. If you remove the green cap at the end of the tranny you'll see it. It can crack and bend when it pushes against the throwout bearing.
  
  http://www.brokevw.com/releasearm.html
• #8 by 1.9TD Caddy on 24 Nov, 2009 04:09
• Thanks to all for all the advice, Today I plan on removing the green cap at the end of the transmission and check on the size of the T/O bearing I replaced. From what I am reading it looks like there are two sizes of bearing. Hopefully it would be the wrong size bearing causing the problem...I keep you posted.
• #9 by Rabbit on Roids on 25 Nov, 2009 08:05
• i bet the finger is broken. i just welded mine back together and closed my eyes. been working great.