Clutch repair
the T4 clutch cover and pressure plate for condition and damage , and check whether the pressure plate is bent.
If damaged, replace the clutch basket assembly. Check the degree of wear of the springs of the clutch disc and the splined surface of the disc hub. If the lining of the driven disk is oily, replace the disk, since it is almost impossible to clean the lining. ♦ Check the lining wear by measuring the distance from the rivet heads to the top surface of the lining with a depth gauge.
If it is about 0.3 mm or less, replace the driven disc. ♦ To measure the lateral runout of the clutch disc, slide it onto an appropriate pin or old input shaft and clamp the shaft at the centers of the lathe.
♦ Mount the indicator with a suitable stand next to the driven disk, put the tip of the indicator against the side surface near the outer perimeter of the disk (see fig. 320). Slowly turn the clutch disc and read the indicator.
Rice. the Volkswagen T4 clutch disc during its repair
♦ If the measured value is greater than 0.4 mm, the disc is considered unusable.
You can try to carefully straighten the driven disk with tongs, but it is recommended to replace it anyway. ♦ Check the clutch disc play on the gearbox input shaft.
To do this, put the clutch disc on the shaft, grasp the outer edge and turn the disc in the direction of rotation and back. If the gap between the splines is more than 0.4 mm, the spline is considered worn. More often, the splined surface of the hub of the driven disk is subject to wear, which in this case must be replaced. ♦ Check the inner ends of the belleville spring for wear. If severe wear is detected (see arrow in Fig. 321), the clutch basket assembly must be replaced.
Rice. 321 Check the wear of the inner ends of the Belleville spring (see arrow) when repairing the T4 clutch
The height of the inner ends of the Belleville spring must be within 0.5 mm.
Strongly bent ends can be bent. Usually, a special device or a strip with a slotted groove, such as a saw key, is used for this. ♦ Place a ruler on the surface of the pressure plate as shown in fig. 322 and measure the gap between the ruler and the surface of the pressure plate with a feeler gauge. If the measured value (wear) is greater than 0.3 mm, the clutch basket assembly must be replaced when repairing the T4 clutch.
Rice. 322 Checking the working surface of the pressure plate
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