Clutch Module

Clutch Module

Special tools, testers and auxiliary items required

• Extractor (T40176)

• Puller (T10037)

• Slide Hammer (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 -.






• Tilt the transmission back slightly to prevent the transmission fluid from leaking when removing the left flange shaft.

- 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 - - arrow -.






- 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 the damaged shaft seals or needle bearings. Refer to => [ Dual Mass Flywheel Needle Bearing ] Dual Mass Flywheel Needle Bearing.

- 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.

Installing

Install in reverse order, paying attention to the following:

- Lubricate the release bearing according to the specification. Refer to => [ Lubricating the Release Bearing ] Clutch Release Mechanism 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 - 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 grease for clutch disc shaft splines (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 => [ (Item 29) Bolt ] Left Flange Shaft, Clutch Module, Spur Gears, Gearshift Shaft and Transmission Cover Overview.