Clutch: Service and Repair

Clutch

Special tools, testers and auxiliary items required

• Flywheel Retainer (3067)

• Centering Pin (T10097)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Centering Mandrel (3176) (For crankshafts with a smaller diameter, or with a needle bearing, refer to => [ Centering the Clutch Disc, Removing and Installing the Pressure Plate on Engines with a Crankshaft with a Smaller Diameter, or Engines with a Needle Bearing in the Crankshaft ] Clutch, Sachs)

• Grease for Clutch Plate Splines (G 000 100)

Removing

- Remove the transmission.

- Install the flywheel retainer (3067) to loosen the bolts.

- Loosen the bolts diagonally and in small steps.

- Remove the pressure plate and the clutch disc.

Installing

Install in the reverse order of removal. Note the following:

• Allocate the pressure plate and the clutch disc to match the engine code.

• Check whether there are alignment sleeves for the engine and transmission in the cylinder block; install if necessary.

• If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).

Clutch Disc Installed Position





• "Getriebeseite" (transmission side) - arrow - faces the transmission.

Checking the Ends of the Diaphragm Spring





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

Checking the Spring and Rivet Connections





- Check the spring connections - arrows A - for damage and make sure the rivet connections - arrows B - are tight.

Only check the position of the adjustment mechanism on a new pressure plate.





• Both edges - A - of the adjusting ring must be located between both notches - arrows B -.

• If the adjusting ring takes on a different position with a new pressure plates, the pressure plate and clutch disc must not be installed.

• With used clutches, the adjusting ring may take on a position outside of the notches.

• Replace the clutch disc and pressure plate if the rivets are damaged or loose.

• Replace the pressure plate and the clutch disc together.

• Allocate the clutch disc and pressure plate to match the engine code.

• To reduce odor caused by a burnt clutch, thoroughly clean the clutch housing, the flywheel and the side of the engine facing toward the transmission.

• Clean the input shaft splines and (on a used clutch disc) the hub splines, remove any corrosion and apply a very thin coating of grease for clutch plate splines (G 000 100) to the splines. Then move the clutch disc back and forth on the input shaft until the hub moves freely on the shaft. Remove any excess grease.

• The pressure plate is corrosion protected and lubricated. Only the running surfaces may be cleaned. Otherwise the service life of the clutch will be shortened considerably.

• The pressure plate contact surface and the clutch disc lining must completely touch the flywheel. Install the bolts.

- Remove the flywheel retainer (3067) when installing.






Engines having a Crankshaft with a Smaller Diameter - arrow -, or Engines having a Needle Bearing - arrow - in the Crankshaft






Centering the Clutch Disc, Removing and Installing the Pressure Plate on Engines with a Crankshaft with a Smaller Diameter, or Engines with a Needle Bearing in the Crankshaft






• Ignore the - arrows A and B -.

Continuation for All

- Position the pressure plate on the alignment sleeves.

- Install all the bolts evenly, by hand, until the bolt heads contact the pressure plate.

- Tighten the bolts in small steps and in diagonal sequence to prevent damaging the centering holes of the pressure plate and the centering pins of the dual mass flywheel. Tightening specification, see - item 4 - in the => [ Clutch Overview ] Clutch Overview.

- Install the transmission.