Jackson Reid
Replacing the clutch on a Citi Golf is a complex process that requires a range of tools and a fair amount of automotive knowledge. It is important to note that the clutch cable in a Citi Golf can fray and snap over time, and it is recommended to replace the unit or arrange a tow to an auto mechanic. To replace the clutch, one must first remove the transmission and then the clutch assembly, which includes the clutch plate, pressure plate, and flywheel. It is also important to adjust the clutch cable tension for optimal performance.
How to replace a clutch cable on a VW Citi Golf
| Characteristics | Values |
|---|---|
| Reason for clutch cable replacement | Age, wear and tear, cable fraying, incorrectly adjusted cable, worn-out components |
| Steps to replace clutch cable | Feed the top end of the cable through the firewall, hook it into the clutch pedal, secure the pedal, feed the bottom end of the cable through the gearbox and release bearing lever, secure locking plates, adjust the clutch cable by turning the adjuster |
| Additional steps for VW Golf 1 Tenacity clutch replacement | Remove everything on top of the gearbox, remove starter, remove gearbox bolts, remove Inner CV bolts, use an engine stand/bar and hook up to the engine, loosen gearbox engine mount, remove bottom bolt, remove top gearbox bolt, slide gearbox out, remove pressure plate bolts, remove pressure plate and clutch plate, remove flywheel |
| Additional tools required | Axle stands, trolley jack, set of spanners |
| Additional parts required | Clutch release bearing, friction points, grease, clutch alignment tool, mounting bolts |
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What You'll Learn
Remove transmission and clutch assembly
To remove the transmission and clutch assembly of a Citi Golf, you will need to first jack up and support your vehicle safely. You will also need the right tools, including axle stands, a trolley jack, and a set of spanners.
Begin by removing everything on top of the gearbox in the engine bay that may obstruct your access. Remove the starter and all gearbox bolts except for one at the middle top and one at the bottom middle. Remove the Inner CV bolts and Inner CVs from the Diff. Use an engine stand or bar to hook up to the engine and then loosen the gearbox engine mount. The complete engine will now hang from the engine bar.
Remove the bottom bolt that is still in place, and if possible, use a gearbox jack. Alternatively, get an assistant to lay under the gearbox and hold it with a normal trolley jack for support. Remove the top gearbox bolt and slowly slide the gearbox out, lowering it gradually with the jack. Once the gearbox is out, remove the pressure plate bolts, pressure plate, and clutch plate.
Now, you can remove the flywheel and either skim it or replace it. If you are reinstalling the old components or just replacing the clutch plate, use a clutch alignment tool to line up the pressure plate and clutch disk. Torque down the bolts and allow the transmission to mate up with the engine.
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Adjusting the clutch cable
Preparation: Park your vehicle on a level surface and engage the parking brake. Loosen the locknut on the clutch cable adjuster, which is located at the lower part of the cable. This will allow you to adjust the tension on the cable.
Adjusting the Tension: Depending on the amount of play in the cable, you will need to turn the adjuster either anti-clockwise or clockwise. If there is excessive play, turn the adjuster anti-clockwise to tighten the cable. On the other hand, if the clutch pedal feels too stiff, turn the adjuster clockwise to allow for more play. The recommended amount of play is about 5 mm.
Final Adjustments: Once you have adjusted the tension to your preference, lock the adjustment in place by tightening the locknut securely. Ensure that the clutch pedal is now level with the brake pedal. Test the clutch by depressing the pedal and observing whether the clutch assembly is activated smoothly.
Advanced Adjustments: If you are experienced in clutch adjustments, you may also consider adjusting the clutch at the end of the cable that connects to the gearbox, as mentioned by some Citi Golf owners. This adjustment involves twisting the bottom of the cable until the level of the paddle feels comfortable and the clutch engages at the right time.
Remember to consult a qualified mechanic or a trusted workshop manual for specific details pertaining to your Citi Golf model.
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Removing the pressure plate
To remove the pressure plate, you must first remove the transmission. Once the transmission is removed, you will be able to see the clutch assembly. If you are lucky, the six clutch access holes will line up with the six cutouts in the pressure plate. If this is the case, simply unbolt the entire clutch, pressure plate, and flywheel combo from the motor with a 10mm triple square.
However, if the clutch access holes do not line up, you will need to separate the pressure plate to remove the clutch. To do this, remove the twelve 6mm triple square bolts holding the pressure plate to the flywheel. Use caution when removing the last bolt on the pressure plate, as it is heavy and will fall off the engine when the last bolt is removed.
Once the pressure plate is removed, you can inspect the clutch plate for wear. If you are reinstalling the old components or just replacing the clutch plate, you will need to use a clutch alignment tool to line up the pressure plate and clutch disk. This will hold everything in place while you torque down the 6mm triple square bolts and allow the transmission to mate up with the engine.
If you are installing a new clutch assembly or kit, it will come with the flywheel, starter ring, pressure plate, and clutch already together and with the installation access holes lined up. Simply line up the bolts with the holes in the crank and bolt the new assembly together.
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Replacing the clutch cable
To replace the clutch cable of a VW Citi Golf, you will need to first unclip the cable from the pedal. Take the cable and feed the top end through the firewall so that the cable’s elongated plastic fitting with the hole can fit into the clutch pedal hook on the other side in the footwell. Hook the cable into the clutch pedal and secure the pedal back on the shaft with its locking clip.
Next, take the bottom end of the cable and feed it through the clutch cable hole in the gearbox. Now feed the cable through the release bearing lever, ensuring its rubber is in place. Secure the cable’s locking plates.
Adjust the clutch cable by turning the adjuster at the lower part of the cable anti-clockwise to tighten the tension on the cable, removing excessive play. Allow about 5 mm of play, then lock the adjustment. The clutch pedal will now be level with the brake pedal, and depressing the clutch pedal will activate the clutch assembly.
You can adjust the clutch by seeing how early or late it takes to release. You can twist the bottom until the level of the paddle is comfortable for you and it catches at the right time.
Some tools you will require are axle stands that can go high enough to create enough clearance for the gearbox to slide out from under the car, a trolley jack, and a set of spanners from 10 to 20 size.
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Tools required
To replace the clutch of a Citi Golf, you will need a range of tools to complete the job. The specific tools required will depend on the model of your Citi Golf and the nature of the repair.
For a VW Citi Golf, you will need a clutch alignment tool to line up the pressure plate and clutch disk. You will also need a 10mm triple square to unbolt the clutch, pressure plate, and flywheel combo from the motor. Additionally, you will need a size 30 socket to remove the CV nut and a spline bit to loosen the bolts holding the inner CVs.
If you are removing the transmission, you will need a range of sockets and wrenches to unbolt the various components. You may also need a new gasket and sealant to ensure a proper seal when reinstalling the transmission.
For a Citi Golf 1.4i, you will need to unclip the cable from the pedal. This may require removing the bracket that holds the cable in place. You will also need to unhook the clutch cable on the gearbox side by turning the white plastics and the nut to loosen the cable.
It is important to have the correct tools for the job to ensure that you do not damage any components or over-tighten bolts. Always refer to a repair manual or seek advice from a qualified mechanic if you are unsure about the tools or procedures required.
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Frequently asked questions
Strange noises when you push in the clutch pedal can indicate a failing bearing. If your clutch slips when the pedal is not depressed, your clutch disc or spring plates may be worn out.
You will need axle stands that can go high enough to create clearance for the gearbox, a trolley jack, and a set of spanners. You will also need a torque wrench and a clutch alignment tool.
First, jack up and support your vehicle. Then, remove the transmission. Next, remove the clutch assembly, pressure plate, and clutch disk. Reinstall the new clutch assembly, pressure plate, and clutch disk, torquing to spec. Finally, adjust the clutch cable by turning the adjuster at the lower part of the cable.
