Replacing the Clutch on a Passat

What a Clutch Does

Disassembled Passat Clutch

A clutch is a mechanical device that allows a car to shift gears. A Passat clutch consists of a pressure plate and a clutch disc. The clutch disc engages the Passat's gears and is connected to the driveshaft (which is attached to the Passat's engine) and the crankshaft (which is attached to the car's transaxle). The transaxle provides power to the Passat's wheels, and the clutch regulates the transfer of power from the Passat's driveshaft to the crankshaft. The only way to repair a slipping clutch in a Passat is to replace it. Replacing a clutch must be done with a great deal of care, since any mistakes can damage the Passat's transaxle and lead to extremely costly repairs.

Removing the Old Clutch from a Passat

Schematic of a Passat Clutch and Mounting

The first step in removing the old clutch is to disconnect the Passat's battery and clutch cables, which are located to the left of the engine and next to the hydraulic cylinder. You will also need to disconnect the backup headlight wires, which run across the Passat's transaxle. Next, jack up the front end of the Passat and place a second jack underneath the engine's oil pan. This second jack will support the engine when you remove the transaxle. Slide underneath the front end of the Passat and unbolt the transaxle from the driveshaft. Slide the transaxle out of the input shaft on the driveshaft, lower the transaxle to the ground and roll it out of the way. You should now be able to access the Passat's clutch, which is mounted on a flywheel on the left side of the engine block. Unbolt the pressure plate and remove it and the clutch disc from the flywheel.

Installing a New Clutch

Clutch Alignment Tool

You should clean the ends of the driveshaft and the crankshaft before installing the new clutch, and you should also inspect the transaxle to make sure it is not damaged or leaking hydraulic fluid. To install the new clutch, make sure the clutch disc is aligned properly with the flywheel. If you look at the center of the clutch disc, you will notice a raised damper hub. This damper hub should face towards the transaxle. You will also need a clutch alignment tool to ensure that the clutch disc is aligned properly with the crankshaft. A clutch alignment tool is a metal bar with a shaft on one end and a ring on the other. Slide the clutch disc onto the alignment tool's shaft and then stick the alignment tool onto the crank shaft through the center of the flywheel. Once the clutch disc is properly aligned and mounted, remove the alignment tool and bolt the pressure plate in place over the clutch disc. Finally, slide the transaxle back into the input shaft on the driveshaft and bolt it into place. Lower the Passat from the jack and reconnect the backup headlight wires, the battery cable and the clutch cable.

Resources

• Clutch Installation Guide