Procedures

Clutch General Repair Information

Special tools, testers and auxiliary items required

• Counter hold tool (10 - 201)

• Locking bar (3067)

• Centering mandrel (3176)

• Torque wrench (VAG 1331)

• Grease for clutch plate splines (G 000 100)

• Refer to general repair instructions.

• Observe the notes on removing and installing master cylinder and slave cylinder. Refer to => [ Master Cylinder and Slave Cylinder ] Master Cylinder and Slave Cylinder.

• On vehicles with Self Adjusting Clutch (SAC) pressure plate (LuK version) an adjuster ring has to be reset when only the clutch plate is replaced. Refer to => [ SAC Clutch Pressure Plate Adjuster Ring Adjusting ] Adjustments.

• To avoid damaging SAC pressure plate when removing and installing, observe assembly instructions for SAC pressure plate. Refer to => [ Clutch with SAC Pressure Plate ] Clutch With SAC Pressure Plate.

• Check that SAC pressure plate is not warped, refer to => [ Check SAC pressure plate for warpage, cracks and burns ] Clutch With SAC Pressure Plate Assembly Overview, LuK

• If the vehicle is installed with a self adjusting clutch (Sachs version), the clutch plate and pressure plate can only be replaced together. Refer to => [ Self Adjusting Clutch Assembly Overview, Sachs ] Self Adjusting Clutch Assembly Overview, Sachs.

• Replace clutch plate and pressure plate if riveted fastening is damaged or loose.

• Select correct clutch plate and pressure plate according to engine code.

• To avoid damaging dual mass flywheel during removal please observe instructions for removal, refer to => [ Removing dual mass flywheel ] Self Adjusting Clutch Assembly Overview, Sachs

• Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines (G 000 100) to the splines. Then move clutch plate backward and forward on input shaft until hub moves freely on shaft. It is important to remove excess grease.

• Pressure plates have an anticorrosion coating and are greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.

• If the clutch has burned out, thoroughly clean the bell housing, flywheel and parts of the engine facing the transmission in order to prevent odors.