How to Replace a Clutch Kit on a VW Caddy II Kombi (9K9B)

Similar Video Tutorial

This video shows the replacement of a similar car part on a different vehicle.

Important! This replacement procedure can be used for the following vehicles: VW Caddy II Kombi (9K9B) 1.4. The steps may vary slightly depending on the vehicle design. This guide was created based on the replacement of a similar car part for: VW Polo III Hatchback (6N1) 1.0.

Replacement: Clutch Kit – VW Caddy II Kombi (9K9B). Tools You May Need:

The following tools are recommended for the clutch kit replacement:

• Wire brush
• WD-40 spray
• Electronic spray
• All-purpose cleaning spray
• Brake cleaner
• Multipurpose lubricant
• Copper paste
• Torque wrench
• Combination wrench 13
• Combination wrench 16
• Socket 10
• Socket 13
• Socket 16
• Socket 18
• Socket 30
• 12-point socket 9
• XZN bit socket 8
• Impact socket for rims 17
• Ratchet wrench
• Flat-head screwdriver
• Pin punch
• Wrench
• Pry bar
• Clutch tool kit
• Engine brace
• Hydraulic transmission jack
• Fender protector
• Wheel chocks

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Replacement: Clutch Kit – VW Caddy II Kombi (9K9B). Tip from AUTODOC:

• Replace the entire clutch kit: the pressure plate, the clutch disc, and the release bearing.
• Please note: all work on the car – VW Caddy II Kombi (9K9B) – should be carried out with the engine switched off.

PERFORM THE REPLACEMENT IN THE FOLLOWING SEQUENCE:

1. Open the hood.
2. Use a fender protector to prevent damage to the paintwork and plastic parts of the car.
3. Unscrew the battery terminal fasteners. Use socket 10. Use a ratchet wrench.
4. Remove the battery terminals.
5. Unscrew the battery fastener. Use socket 13. Use a ratchet wrench.
6. Remove the battery.
7. Unscrew the battery bracket fasteners. Use socket 10. Use a ratchet wrench.
8. Remove the battery bracket.
9. Disconnect the clutch cable.
10. Disconnect the engine wiring harness connector.
11. Loosen the engine wiring harness.
12. Unscrew the ground cable fastener. Use combination wrench 13.
13. Disconnect the ground cable.
14. Unscrew the starter motor fasteners. Use socket 13. Use a ratchet wrench.
15. Unscrew the fasteners connecting the gearbox to the engine block. Use socket 18. Use a ratchet wrench.
16. Secure the wheels with wheel chocks.
17. Unscrew the driveshaft fastener. Use socket 30. Use a wrench.
18. Loosen the wheel hub bolts. Use an impact socket for rims #17.
19. Lift the front of the car and secure it on stands.
20. Unscrew the wheel bolts.
21. Remove the wheel.
22. Unscrew the fastener connecting the driveshaft to the wheel hub. Use socket 30. Use a ratchet wrench.
23. Remove the retaining nut.
24. Disconnect the gearbox sensor connector.
25. Clean the fasteners connecting the ball joint to the suspension arm. Use a wire brush. Use WD-40 spray.
26. Loosen the fastener connecting the ball joint to the suspension crossmember. Use socket 13. Use a ratchet wrench.
27. Loosen the ball joint from the control arm.
28. Disconnect the driveshaft from the steering knuckle.
29. Unscrew the fasteners of the driveshaft joint. Use XZN #8. Use a ratchet wrench.
30. Remove the driveshaft.
31. Secure the engine. Use an engine brace.
32. Unscrew the cable bracket fasteners. Use combination wrench 16.
33. Unscrew the shift cable fastener. Use socket 13. Use a ratchet wrench.
34. Remove the shift cable retaining clip. Use a flat-head screwdriver.
35. Clean the gearbox mount fasteners. Use a wire brush. Use WD-40 spray.
36. Unscrew the fasteners connecting the gearbox mount to the gearbox. Use combination wrench 16.
37. Clean the gearbox mount fasteners. Use a wire brush. Use WD-40 spray.
38. Unscrew the gearbox mount fasteners connecting to the subframe. Use socket 13. Use a ratchet wrench.
39. Remove the gearbox mount.
40. Support the gearbox from below. Use a hydraulic transmission jack.
41. Clean the gearbox mount fasteners. Use a wire brush. Use WD-40 spray.
42. Unscrew the gearbox mount fasteners. Use socket 18. Use a ratchet wrench.
43. Unscrew the fasteners connecting the gearbox mount to the body. Use socket 13. Use a ratchet wrench.
44. Remove the gearbox mount.
45. Unscrew the fasteners connecting the gearbox mount to the gearbox. Use combination wrench 16.
46. Remove the lower gearbox mount.
47. Unscrew the fasteners connecting the gearbox to the engine block. Use socket 18. Use a ratchet wrench.
48. Move the gearbox aside.
49. Remove the support under the gearbox.
50. Remove the gearbox.
51. Remove the release bearing. Use a pry bar.
52. Unscrew the pressure plate fasteners. Use the 12-point socket 9. Use a ratchet wrench.
53. Remove the pressure plate along with the clutch disc. Use a pry bar.
54. Clean the clutch kit mounting seats. Use all-purpose cleaning spray.
55. Install the new pressure plate along with the clutch disc.
56. Screw in the pressure plate fasteners. Use the 12-point socket 9. Use a ratchet wrench.
57. Align the clutch disc. Use a pry bar.
58. Screw in the pressure plate fasteners. Use the 12-point socket 9. Use a ratchet wrench.
59. Install the flywheel locking tool. Use a clutch tool kit.
60. Tighten the pressure plate fasteners. Use the 12-point socket 9. Use a torque wrench. Tighten it to 27 Nm torque.
61. Remove the flywheel lock.
62. Treat the release bearing mounting seat. Use multipurpose grease.
63. Install the new release bearing.
64. Support the gearbox from below. Use a hydraulic transmission jack.
65. Install the gearbox.
66. Attach the gearbox to its mounting point.
67. Screw in the fasteners connecting the gearbox to the engine block. Use socket 18. Use a ratchet wrench.
68. Tighten the fasteners connecting the gearbox to the engine block. Use socket 18. Use a torque wrench. Tighten it to 64 Nm torque.
69. Install the lower gearbox mount.
70. Screw in the fasteners connecting the gearbox mount to the gearbox. Use combination wrench 16.
71. Tighten the fasteners connecting the gearbox mount to the gearbox. Use combination wrench 16. Use a torque wrench. Tighten it to 64 Nm torque.
72. Install the gearbox mount.
73. Screw in the fasteners connecting the gearbox mount to the body. Use socket 18. Use a ratchet wrench.
74. Tighten the fasteners connecting the gearbox mount to the body. Use socket 13. Use a torque wrench. Tighten it to 38 Nm torque.
75. Tighten the fasteners connecting the gearbox mount to the gearbox. Use socket 18. Use a torque wrench. Tighten it to 69 Nm torque.
76. Remove the support under the gearbox.
77. Install the gearbox mount.
78. Screw in the fasteners connecting the gearbox mount to the subframe. Use socket 13. Use a ratchet wrench.
79. Tighten the fasteners connecting the gearbox mount to the subframe. Use socket 13. Use a torque wrench. Tighten it to 49 Nm torque.
80. Tighten the fasteners connecting the gearbox mount to the gearbox. Use combination wrench 16. Use socket 16. Use a torque wrench. Tighten it to 75 Nm torque.
81. Tighten the fasteners connecting the gearbox to the engine block. Use socket 18. Use a torque wrench. Tighten it to 64 Nm torque.
82. Attach the shift cable retaining clip.
83. Screw in the shift cable fastener. Use socket 13. Use a ratchet wrench.
84. Screw in the cable bracket fasteners. Use socket 16. Use a ratchet wrench.
85. Tighten the cable bracket fasteners. Use socket 16. Use a torque wrench. Tighten it to 22 Nm torque.
86. Clean the CV joint mounting seat. Use all-purpose cleaning spray.
87. Install the driveshaft.
88. Screw in the fasteners of the driveshaft joint. Use XZN #8. Use a ratchet wrench.
89. Clean the CV joint splines of the driveshaft. Use a wire brush. Use WD-40 spray.
90. Attach the steering knuckle to the driveshaft.
91. Connect the ball joint to the control arm. Use a pin punch.
92. Screw in the fastener connecting the ball joint to the control arm. Use socket 13. Use a ratchet wrench.
93. Tighten the fasteners of the driveshaft joint. Use XZN #8. Use a torque wrench. Tighten it to 42 Nm torque.
94. Attach the retaining nut.
95. Screw the nut onto the driveshaft. Use socket 30. Use a ratchet wrench.
96. Tighten the fasteners connecting the ball joint to the control arm. Use socket 13. Use a torque wrench. Tighten it to 55 Nm torque.
97. Connect the gearbox sensor connector.
98. Treat the surface where the brake disc contacts the rim. Use a copper lubricant.
99. Clean the brake disc surface. Use a brake cleaner.
100. AUTODOC recommendation: Clutch kit replacement – VW Caddy II Kombi (9K9B). Allow a few minutes after applying the spray.
101. Mount the wheel.
102. AUTODOC recommendation: Important notice! Hold the wheel while screwing in the fasteners. VW Caddy II Kombi (9K9B)
103. Screw in the wheel bolts. Use an impact socket for rims #17.
104. Lower the car.
105. Tighten the driveshaft nut. Use socket 30. Use a torque wrench. Tighten it to 175 Nm torque.
106. Tighten the wheel bolts in a star pattern. Use an impact socket for rims #17. Use a torque wrench. Tighten it to 120 Nm torque.
107. Remove the jack and wheel chocks.
108. Remove the engine brace.
109. Tighten the fasteners connecting the gearbox to the engine block. Use socket 18. Use a torque wrench. Tighten it to 64 Nm torque.
110. Tighten the starter motor fasteners. Use socket 13. Use a torque wrench. Tighten it to 29 Nm torque.
111. Attach the engine wiring harness.
112. Connect the ground cable.
113. Screw in the ground cable fastener. Use combination wrench 13.
114. Treat the engine wiring harness connectors. Use dielectric grease.
115. Connect the engine wiring harness connector.
116. Fasten the clutch cable.
117. Install the battery bracket.
118. Screw in the battery bracket fasteners. Use socket 10. Use a ratchet wrench.
119. Mount the battery.
120. Screw in the battery fasteners. Use socket 13. Use a ratchet wrench.
121. Attach the terminals to the battery.
122. AUTODOC recommendation: Clutch kit replacement – VW Caddy II Kombi (9K9B). Be careful! Do not mix up the positive and negative terminals of the car battery.
123. Screw in the battery terminal fasteners. Use socket 10. Use a ratchet wrench.
124. Treat the battery terminals. Use dielectric grease.
125. Let the engine run for a few minutes. This is necessary to ensure the component is functioning correctly.
126. Turn off the engine.
127. Remove the fender cover.
128. Close the hood.

WELL DONE! ?

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DISCLAIMER: The document contains only general recommendations that may be helpful to you when performing repair or replacement operations. AUTODOC is not liable for any losses, injuries, or property damage that occur during the repair or replacement process due to incorrect application or misinterpretation of the provided information.

AUTODOC is not liable for any possible errors and uncertainties in this guide. The information is provided for informational purposes only and cannot replace the instructions of a specialist.

AUTODOC is not liable for the incorrect or dangerous use of equipment, tools, and car parts. AUTODOC strongly recommends being careful and observing safety rules when performing repair or replacement operations. Remember: Using low-quality car parts will not guarantee the correct level of road safety.

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