Clutch, Servicing

Clutch, servicing





Special tools and equipment
^ 3067 counterhold
^ 3176 Centering mandrel
^ VAG 1331 Torque wrench

Note:
^ Follow general repair instructions.
^ Replace clutch plates and pressure plates where riveted joint is damaged or loose.
^ Assign clutch plate and pressure plate by way of engine code.
go to Parts catalog
^ Clean input shaft splines and - in the case of used clutch plates - hub splines, remove corrosion and apply extremely thin layer of grease G 000 100 to splines. Then move clutch plate back and forth on input shaft until hub moves freely on shaft. Excess grease must be removed.
^ Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, as otherwise the clutch service fife will be considerably shortened.
^ To reduce the odor nuisance of a scorched clutch, thoroughly clean bell housing, flywheel and parts of engine facing transmission.





For servicing the clutch first remove the transmission.
A - Paint dot on dual-mass flywheel
^ If present, white paint dot -A- on dual-mass flywheel must be aligned with white paint dot -B- on pressure plate

B - Paint dot on pressure plate
^ If present, white paint dot -A- on dual-mass flywheel must be aligned with white paint dot -B- on pressure plate

1 - Dual-mass flywheel
^ Make sure centering pins are a tight fit
^ Locating face for clutch lining must be free from grooves, oil and grease
^ removing and installing
2 - Bolt for flywheel
^ Always replace
^ Bolt length 22.5 mm 60 Nm plus additional 90° turn
^ bolt length 43 mm 60 Nm plus additional 180° turn
3 - Clutch plate
^ Installation position:
- Damping set (coil springs) toward pressure plate or transmission
- Lining of clutch plate must be located against flywheel
- Writing Getriebeseite, if present, toward pressure plate or transmission
^ Do not lubricate
^ Diameter of clutch plate
^ Centering
^ Slightly lubricate splines
4 - Pressure plate
^ Removing and installing
^ Checking ends of diaphragm spring
^ Checking spring attachment and rivet attachments
^ If present, line up white paint dots on flywheel -A- and pressure plate -B-, with one another during assembly.

5 - Bolt, 25 Nm
^ Loosen and tighten gradually in diagonal sequence

6 - Needle bearing
^ Removing and installing

Fig. 1 Centering clutch plate and removing/installing pressure plate:

- Loosen and tighten bolts gradually in diagonal sequence - 25 Nm.
- Reverse position of counterhold 3067 when removing.
- Installation position of clutch plate: Damping set (coil springs) or writing Getriebeseite must face pressure plate or transmission.
- Only install attachment bolts once contact surface of pressure plate and lining of clutch plate are located completely on flywheel.
- Use centering mandrel 3176 to center clutch plate.
- During assembly ensure that white paint dots, if present, on dual-mass flywheel -A- and pressure plate -B- are lined up with one another.

Fig. 2 Checking ends of diaphragm spring:

^ Wear down to half the diaphragm spring thickness is permissible.

Note: When performing repairs, always assign clutch pressure plate and clutch plate by way of engine code in fine with Parts catalog.

Fig. 3 Checking spring attachment and rivet attachments:

- Check spring attachment between pressure plate and cover for cracks, check rivet attachments are secure.
- Replace clutches showing damaged springs or loose rivet attachments -arrows-.