Mark,
Have you replaced the seals and the bronze bushing at the
front end of the input shaft??? If that bronze bushing is badly
worn, the clutch pushrod will wobble all over the place and never
make proper contact. VW has a kit that includes both seals and the
bushing, just make sure you tell them whether it is for an 8V or 16V
gearbox as the input shafts are different sizes.
To replace the bushing I've always removed either the 5th
gear housing itself (usually put new release bearing in at the same
time) or popped the green cover off and, once the pushrod is out of
the way, slid a 3ft long smooth, 3/8" steel rod in. A few taps with
a hammer will move the bushing out. Before you do this, measure how
far back the bushing sits inside the input shaft. Tap the new one
back in to the correct depth (I use a deepwell 10mm socket) and then
replace the seals. Job done!!!....Jack
ONE MORE QUESTION.... I've pulled two used clutches now that have had
the thrust plate worn off-center... meaning that the push rod wasn't
making contact with the center of the thrust plate. How does that
happen and is there a way to make sure it never happens?
