Volkswagen Diesel Rabbit, Jetta, Pickup Repair Manual 1977-1984 by Haynes

CLUTCH RELEASE MECHANISM | REMOVAL AND INSTALLATION

1. The clutch release mechanism is accessible after removal of the transmission end cover plate. Undo the four securing screws and remove the cover plate (photo). The clutch torque shaft with its finger is now visible (Fig. 4.8).



2. The finger is held in place by two circlips and a spring. The two circlips can now be removed and the shaft, finger and return spring removed from the casing (photos).



3. Lift out the clutch release bearing and guide sleeve (photo). The pushrod cannot be withdrawn until the transmission is in the car.



4. Rotate the clutch release bearing: if it is noisy or feels rough it must be replaced. Inspect the shaft oil seal for wear or deterioration and replace it, if necessary.



5. Refitting is the reverse of the removal procedure. When fitting the return spring ensure that the bent ends bear against the transmission casing and the center part hooks into the clutch finger (photo). Always use a new gasket when fitting the end cover.

WHEEL BEARING HOUSING | REMOVAL AND INSTALLATION

1. With the vehicle standing on all four wheels undo the axle nut and slacken the wheel studs. Jack-up the front wheels and support the vehicle on axle stands. Remove the front wheel.



2. Remove the nut from the tie-rod balljoint and break the joint using a wheel puller.



3. Undo the clamp bolt and remove the steering balljoint from the wheel bearing housing. Push the wishbone down out of the way.



4. Remove the brake caliper, refer to Chapter 6, and tie it up out of the way with a piece of wire or cord. Do not allow it to hang by the brake hose.



5. Undo the crosshead screw securing the brake disc to the hub and remove the disc.



6. At this point there is a choice in procedure. Either remove the strut complete by undoing the nuts securing it to the frame in the engine compartment or remove the wheel bearing housing from the strut.
   
   The second method involves marking the camber adjustment bolt, so that it may be reassembled with the same camber adjustment, removing it and the lower bolt and then drawing the housing off the bottom of the strut and at the same time pulling it off the driveshaft splines.
   
   We found it easier to remove the wheel bearing housing from the strut. Whichever way you do it the bearing housing may now be removed from the car.



7. Assembly is the reverse of removal. If you have disturbed the camber angle set it as near as you can and have it checked when you go the VW agent to have a new axle nut fitted to the correct torque.

WHEEL BEARING (FRONT) | REMOVAL AND REFITTING

1. The removal of a wheel bearing is a lengthy job so it is as well to be sure that it is actually necessary before doing the job. A defective bearing will make a rumbling noise under load.
   
   Jack-up the suspect wheel and test the rim rock. Spin the wheel and listen for noise indicating war. A good bearing will make little or no noise. If you are not sure, consult someone with experience because a defective race could cause a lot of trouble and, if it collapses, a nasty accident.



2. Having decided that it is necessary; remove the wheel bearing housing as described in Section 10. The next job is to press the hub out of the bearing race and for this job a press is necessary with the correct sized mandrels.

• Tune-up and routine maintenance
• General engine overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Driveline
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams