Clutch Assembly

- Inspect parts of clutch and, if necessary, replace.





- Place the pressure plate on a level plate in a press for preloading. Bearing surface on pressure plate MUST NOT scrape on pressure plate housing while pressing together.





- Slide 4 mm thick locally made wire tool underneath bolt heads of new version pressure plate.





- Inspect ball socket bushing (snap ring) in release lever. If necessary, install a new ball socket bushing and press in against stop with Special Tool VW 421. Vent hole in release lever must not be covered, otherwise ball socket bushing would spring back when air can't escape.





- Lubricate bearing surface of release bearing in release lever as well as both sides of preload washer for pressure plate in area of release bearing with Optimoly HT. Mount release bearing with washer and release lever on pressure plate. Gap of circlip should be between retainer on release bearing or offset to groove in release bearing when bearing has an opening.





- Check position of two 6 mm centering pins, correcting if necessary. Protrusion of pins over bearing surface of intermediate plate on flywheel: 3.5-0.5 mm (distance A).





- Push intermediate plate in direction of release bearing on the three adjusting elements.





- Assemble clutch, observing the following points:
a) Yellow arrows on discs are mounted 180° opposite (residual unbalance).
b) White mark on disc (without spring-loaded liner) faces flywheel.
c) Hubs of discs face release bearing.
d) Transfer residual unbalance mark of discs (yellow arrows) to engine side of same (facilitates assembly work).
e) Mark pressure plate before installing; drive pressure plate of dowel pin centered clutch on to centering pins or into intermediate plate with a plastic hammer far enough, so that the drive plate located between both can still be moved with short drive shaft (central shaft I).
f) Pressure plate and intermediate plate are also marked with dots of white paint (residual unbalance/heavy side), which are mounted offset 180° (opposite). This must be considered when replacing one or both parts.
g) Recheck protrusion of centering pins on flywheel (3.5 - 0.5 mm), correcting if necessary.
h) Lubricate parts to specifications; however, lubricate the starter ring after installation of the clutch. Lubricate guide tube for the release bearing.

NOTE: Remove wire clips after installation of clutch.