JBugs Video Series

1971 VW Super Beetle - Clutch Installation:

Video Overview:

Before we can install the engine in our 1971 Super Beetle, we have to reassemble it since we took all the accessories off after it was last shown on video for painting. We cover the assembly much earlier on in this series, so we won’t go back through it. We did put together a time lapse if you’d like to watch though. After the assembly, we’ll install a clutch, pressure plate and throw out bearing. The installation is pretty straight forward, there isn’t much too it but our tech will cover some of the differences in late model versus early model clutches. While we’re preparing, we will fill our transmission with gear oil and install a fuel hose and filter on the chassis that will hook up to the engine later, follow along and enjoy!

Video Tips:

Tools used in this video:
17mm Wrench
Flywheel Lock
Clutch Alignment Tool
3/8” Ratchet with Extension
13mm Socket
17mm Allen Driver
Linesman's Pliers

Chemicals Used:
85W90 Gear Oil

Video Transcript:

Hi! I'm Sam with JBugs.com
I'm going to adjust my clutch cable, while you guys watch me install a clutch.
In our last video, we got the engine compartment of our 1971 Super Beetle ready for and engine.
That's the engine that we build over two and a half years ago.
After it was featured in its last video, we ran the engine for about three hours total.
Then, we pulled it apart down to the long block so we could retorque the cylinder heads and paint the engine tin and accessories.
That was in July of 2019 and now, two years later, we'll finally get the engine reinstalled.
We aren't going to go over the engine build in detail again but we did film a time lapse of the process so you can see the engine going back together.
We went a little overboard with the assembly as we're going to have to pull the rear engine tin, pulley tin, and fan shroud hoses to install the engine along with the oil filter and hoses.
We'll also end up removing the carburetor, alternator pulley belt, and tensioner to clear the rear apron but we wanted to show the completed engine out of the car.
With the engine complete, we drop the engine from the stand onto our engine dolly, with the help of an assistant, so we can install a clutch.
We bolt in a flywheel lock to keep the engine from turning over then we grease the pilot bearing inside the gland nut.
The flywheel, pressure plate, and disc, are cleaned to remove any oil, grease, debris, or dirt,
The sprung stock replacement Valeo clutch disc is set into the flywheel using a clutch alignment tool.
Then, a stock replacement Sachs German pressure plate is loosely bolted in place.
Since we have a late model transmission, our pressure plate doesn't have a centering ring like 1970 and earlier units.
The ring is built into the throughout bearing on later models.
The throughout bearing also has built in clips and a centering ring to align it with the transmission.
Once the pressure plate is loosely bolted in place, we can tighten the bolts, a little bit at a time, to depress the clutch evenly.
You can see the fingers of the clutch flatten out as we tighten the pressure plate down.
Once the pressure plate is fully seated, evenly on the flywheel, the bolts are torqued down to about 20-foot-pounds.
The alignment tool, and the flywheel lock are removed.
Then at the transmission, we'll pull the fill plug and pour in about seven quarts of 85W90 gear oil.
We do this while the car is on all four wheels and pour the oil in until it is level with the fill plug.
Then, the fill plug is threaded back in place.
While we're working at the transmission, we'll get the new throughout bearing installed.
Here we can see how the centering ring on the bearing keeps is aligned with the collar on the transmission.
The collar and the arms of the throughout shaft are lightly greased.
Then, the bearing is set in place and the clips are bent down and over the back of the arms to hold it in place.
And we'll install a length of fuel hose, with a filter, onto the chassis steel line.
We'll trim the hose as needed once the engine is installed, in our next video.
Thanks for watching!
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And when you need parts for your vintage VW, stop by JBugs.com