Volkswagen Repair: VW Clutch, diesel rabbit, clutch assembly

Question
I know this is not your area of expertise, but I have a question on a 84 diesel rabbit 5 speed.  The clutch on it will not disengage even when moving the lever on the transmission by hand.  My question is:  Is this a sign that the clutch is worn out or Is the mechanism that disengages the clutch broke in the transmission?  Any advice will be greatly appreciated.

Answer
Jerome,

There could be anyone of three problems with your clutch assembly.  I don't think you'll have a problem with your clutch disc or pressure plate themselves.

1. Remove the green cover(with VW logo) at the back of the transmission, have a container to catch the oil that will leak under it. Have someone apply the clutch peddle and observe the movement of the small lever on the throwout bearing.  If the lever is split you'll need to disconnect the clutch cable and remove the spring clip on the lever.  Then pull out the shaft and replace the lever (They only fit one way).

2. If the lever is OK, remove the throwout bearing under the lever by removing the clutch cable and the plastic stop on the clutch arm to swing the strait down to clear the shaft, and pull out the bearing.  Inspect the bearing for damage and note the location of the pushrod behind the bearing (it should be sticking out about an inch. If it is not you have problem 3).

3. Put a new green cover on the back of the transmission, and remove the transmission.  The plate that centers the purshrod in the pressure plate is damaged and needs to be replaced.  If this is the problem, I would recommend that you replace the seals in the bell housing and install a complete clutch kit, as this wear would indicate an old clutch assembly.

Good Luck,

Paul