Clutch Module
Clutch Module
Special tools, testers and auxiliary items required
• Puller (T40176)
• Extractor (T10037)
• Slide Hammer-Complete Set (VW 771/1)
• Grease for Clutch Disc Shaft Splines (G 000 100)
• Sealing Grease (G 052 128 A1)
Removing
- Remove the transmission and secure it on the transmission support (T40173) using the tensioning strap - 1 -.
• To prevent transmission oil from leaking when removing the left flange shaft, tilt the transmission back slightly.
- Remove bolts - arrows - on left flange shaft mounting bracket.
- Remove the flange shaft from the transmission in the direction of - arrow A -. Keep the end of the shaft - 2 - centered on the front final drive opening - arrow 3 -.
Danger of damaging the shaft seal.
• If the shaft is not centered when removing, the shaft splines - 2 - fall onto the inner shaft seal - arrow 3 - between the final drive and the transmission housing.
• Always replace a damaged shaft seal. Refer to => [ Left Flange Shaft Seal with Transmission Removed ] Left Flange Shaft Seal With Transmission Removed.
• If it is not possible to remove the left flange shaft by hand, then use the (VW 771) to remove it.
- Attach the plate from the (T10037) to the flange shaft - arrows - and attach the spindle from the (VW 771) (nuts - A -).
- Secure the (T40176) to the clutch module - A - with the nut - B -- arrows -.
- Rotate the (T40176) upward.
Danger of damaging the shaft seals and the needle bearings in the dual mass flywheel.
• The clutch module weighs approximately 20 kg.
• To prevent the clutch module from tipping, counterhold it at the bottom as shown in the illustration.
• When removing and installing the clutch module, make sure the shaft seals and the needle bearing in the dual mass flywheel - arrow - are not damaged.
• Replace damaged shaft seals or needle bearings. Refer to => [ Dual Mass Flywheel Needle Bearing, Sachs and LuK ] Dual Mass Flywheel Needle Bearing, Sachs and LuK.
- Remove the clutch module without tilting the input shaft - arrow -.
Danger of causing damage to the transfer plate on the dual mass flywheel.
• Do not lay the clutch module on one side on the transfer plate - arrow -.
• This could bend the transfer plate - arrow -, which will then lead to functionality problems.
- Lay the clutch module on a work bench with the clutch pressure plate facing down.
4-Cylinder TDI Vehicles (Except 125 kW TDI)
Check which version of the needle bearing is inside the dual mass flywheel.
• Needle bearings is missing the 4th roller - arrows - must be replaced on 4-cylinder TDI vehicles (except 125 kW TDI). Refer to => [ Dual Mass Flywheel Needle Bearing, Sachs and LuK ] Dual Mass Flywheel Needle Bearing, Sachs and LuK.
• New needle bearings are equipped with rollers.
• On all other vehicles, the missing 4th roller is not a defect in the needle bearing. Do not replace the needle bearing!
Install the Clutch Module
Install in reverse order, paying attention to the following:
- Lubricate the release bearing according to the specification => [ Lubricating the Release Bearing ] Clutch Release Mechanism Assembly Overview.
- Always clean the left flange shaft, the transmission housing in the area where the differential is accessed - arrow A - and the shaft seal - arrow B -.
• Replace the shaft seal between the differential and transmission housing. Refer to - arrow B - if it is damaged. Refer to => [ Left Flange Shaft Seal with Transmission Removed ] Left Flange Shaft Seal With Transmission Removed.
- Fill the area between the sealing lip and dust lip - arrow B - halfway with sealing grease (G 052 128 A1).
- Clean the input shaft - arrow -.
- Lightly grease the input shaft splines with clutch disc spline grease (G 000 100).
Remove any grease on the pivot pin on the input shaft - arrow - all the way up to the splines before installation.
- Slide the clutch module onto the input shaft carefully without tilting it.
- Remove the (T40176) from the clutch module.
- Rotate the clutch module - 1 - until the opening to the differential - arrow 3 - is seen.
- Insert the left flange shaft into the transmission in the direction of - arrow B - and guide the end of the shaft - 2 - into the shaft seal on the front differential - arrow 3 -, keeping the shaft centered.
Danger of damaging the shaft seal.
• If the shaft is not centered, the shaft splines - 2 - will damage the shaft seal - arrow 3 - between the differential and transmission housing.
• Always replace a damaged shaft seal. Refer to => [ Left Flange Shaft Seal with Transmission Removed ] Left Flange Shaft Seal With Transmission Removed.
- Tighten the left flange shaft mounting bracket - arrows -. Tightening specification - 30 - => [ Bolt ] Left Flange Shaft, Clutch Module, Side Shaft, Gearshift Shaft and Transmission Cover Assembly Overview.