Procedures

Clutch, Servicing

• Refer to general repair instructions. Refer to => [ General Repair Information ] General Repair Information.

• It is necessary to remove the transmission in order to work on the clutch.

• To prevent damaging the clutch pressure plate while removing or installing, pay close attention to the installation instructions. Refer to => [ Clutch Pressure Plate and Clutch Plate, Sachs ] Clutch Pressure Plate and Clutch Plate, Sachs and => [ Clutch Pressure Plate and Clutch Plate, LuK ] Clutch Pressure Plate and Clutch Plate, LuK.

• With clutch pressure plate (manufactured by LuK), an adjusting ring must be reset if only clutch plate is replaced. Refer to => [ Clutch Pressure Plate Adjusting Ring, LuK, Resetting ] Adjustments.

• Check the clutch pressure plate for deformation => [ Clutch Pressure Plate, Checking for Distortion, Cracks and Burn Marks ] Clutch, Sachs Assembly Overview and => [ Clutch Pressure Plate, Checking for Distortion, Cracks and Burn Marks ] Clutch, LuK Assembly Overview.

• Replace clutch plates and clutch pressure plates that have damaged or loose rivets.

• Allocate the pressure plate and clutch pressure plate according to the engine codes. Refer to the => Electronic Parts Catalog.

• The clutch pressure plates are corrosion-protected and greased. With the exception of the friction surface on the clutch plate, do not clean the pressure plate. This will shorten the service life of the clutch considerably.

• The friction surfaces on the pressure plate and on the dual mass flywheel must be cleaned thoroughly (degreased).

• To reduce odor caused by a burnt clutch, thoroughly clean the transmission housing around the clutch as well as the engine on the transmission side.

• If the surface of the input shaft is visibly damaged near the needle bearing in the dual mass flywheel - arrow -, then replace both the input shaft and the needle bearing. Refer to => [ Dual Mass Flywheel Needle Bearing, Sachs and LuK ] Dual Mass Flywheel Needle Bearing, Sachs and LuK.





• Check the input shaft near the bearing in the drive plate - arrow - for scoring. Replace the needle bearing in the drive plate if necessary.





• Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant (G 000 100) on splines. Then move clutch plate back and forth on input shaft until the hub moves freely on the shaft. Excess grease must be removed.

• Remove the grease on the pivot pin up to the splines.

• Check the plastic washer - A - on the dual mass flywheel "manufactured by Sachs" for wear => [ Check the Plastic Washer Inside the Dual Mass Flywheel Manufactured by Sachs ] Clutch, Sachs Assembly Overview.





• Check which version of the needle bearing is inside the dual mass flywheel - arrow - and replace if necessary => [ Checking the Needle Bearing Inside the Dual Mass Flywheel on a 4-Cylinder TDI Vehicle: Vehicle (except on the 125 kW TDI) ] Clutch, Sachs Assembly Overview.

• Rattling noises can occur when pressing the clutch if there is not enough grease on the release bearings - arrows -





• Lubricate the release bearings - arrows - with adhesive lubricating paste (G 000 150).

• 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.