Clutch: Service and Repair

Clutch

Special tools, testers and auxiliary items required

• Retainer (3067)

• Centering mandrel (T10097)

• Torque wrench (V.A.G 1331)

• Grease for clutch plate splines (G 000 100)

Removing

- Remove transmission --> [ Transmission, Removing ] Transmission, Removing.

- Insert flywheel retainer (3067) to loosen bolts.

- Loosen bolts in small stages in diagonal sequence.

- Remove pressure plate and clutch plate.

Installing

Installation is the reverse of removal, noting the following:

• Allocate pressure plate and clutch plate via engine code.

• Self adjusting pressure plate adjusting ring, checking and resetting in LuK clutches --> [ Self-Adjusting Pressure Plate Adjusting Ring, New LuK Clutch, Checking and Resetting ] Procedures.

• Make sure alignment sleeves for engine to transmission are installed in cylinder block, install if necessary.

• If alignment sleeves are not present, shifting difficulties, clutch problems and possibly noise in transmission (loose gear rattling) will occur.

Installation Position of Clutch Plate





• Marking "transmission side" - arrow - faces transmission.

Checking Ends of Diaphragm Spring





• Wear up to half the thickness of diaphragm spring - arrow - is permitted.

Check Connections of Springs and Rivets





- Check spring connections - arrows A - for damage and rivets - arrows B - for secure seating.

• Replace clutch plates and pressure plates with damaged or loose rivets.

• pressure plate and clutch plate must only be replaced together.

• Allocate clutch plate and pressure plate via engine code.

• If the clutch has burnt out, thoroughly clean the bell housing, flywheel and parts of the engine facing the transmission in order to reduce the smell of burnt linings.

• 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 on input shaft back and forth until hub on shaft moves easily. Always remove excessively applied grease.

• Pressure plates are protected against corrosion and greased. Only the contact surface may be cleaned, otherwise service life of clutch is significantly reduced.

• Contact surface of pressure plate and clutch plate lining must make complete contact on flywheel. Only then insert mounting bolts.

- Change over flywheel retainer (3067) when installing.





- Place pressure plate onto alignment pins.

- Screw in all bolts uniformly by hand until bolt head makes contact on pressure plate.

- Tighten bolts in small stages in diagonal sequence in order to prevent damage to centering holes of pressure plate and centering pins of dual mass flywheel.

- Install transmission --> [ Transmission, Installing ] Transmission, Installing.