[Vwdiesel] clutch problems

[Sandy Cameron]

At 11:51 AM 05/12/2006 -0330, you wrote:
>
>
>Hi everyone,
>
>I'm new on this forum reading post in the background trying to learn
>more about my diesels. I have been working on Vw for a long time most
>times its just repair or replace issues. Last year I decided on doing a
>switch of engines in my 92 gas 1.8l jetta to a 1.6l diesel engine. It
>has been an ongoing saga of problems mostly due to my own faults. Anyway
>the 1.6 engine came from an 84 jetta. To make a long story short the
>clutch that was on the diesel engine was a 200 mm diameter. I lost that
>clutch last week. I have lots of scrapped vws to rob parts from so I
>took a clutch from an 88 Carat. It's worn but still usable. Of course
>this clutch is a 210mm. I had a pressure plate and flywheel from the
>original 1.8 gas engine (210mm)that I decided to use with the friction
>plate from the 88 carat. So here is my problem/question. After adjusting
>the clutch cable I can't get the clutch to disengage. It is almost
>disengaging but not enough to make shifting easy. Does any one know if
>there is a difference between the 210mm clutches among the jetta range
>gl as oppose to the carat. Also is there a difference between the 200
>and 210 other than diameter and has anyone used a 210mm clutch on a
>diesel engine?  The gear box I have in the car presently was used with
>the 1.8 gas. I have to take the clutch out again at which time I will
>measure the heights of the 200mm and 210mm pressure plates but I would
>like to know before hand. If I got to put a 200mm clutch kit in I have
>to order one that will take a week to get.


When you get it apart, ensure the plate slides freely on the tranny spline.

esp. if the plate is form a clutch that has been out of use for a while. I
have seen trannies, stored indoors, where the spline had a thin coat of rust
that had to be removed tu let the plate slide on the spline freely..
Sure sucks to find this out after you put it all together.

Sandy