Repairing clutch

Make

Volkswagen

Model

Polo Mk5

Section

6-speed manual gearbox 02U › Clutch, control › Repairing clutch

Power transmissionRepairing clutch

Repairing clutch

Special tools and workshop equipment required

t	Counterhold -3067-

t	Centring mandrel -T10086-

t	Torque wrench -V.A.G 1331-

t	Grease for clutch plate splines -G 000 100-

  Note

t	Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

t	If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

t	Renew clutch plates and pressure plates with damaged or loose rivets.

t	Allocation → Electronic parts catalogue „ETKA“

1 -

Flywheel

q	Ensure that centring pins fit tightly

q	Contact surface for clutch lining must be free of grooves, oil and grease

q	Removing and installing → Rep. gr.13

2 -	Clutch plate

q	Allocate according to → Electronic parts catalogue „ETKA“.

q	Installation position: spring cage faces pressure plate.

q	Centring → Fig.

q	Lightly grease splines

  Note

Clean input shaft splines and, on used clutch plates, hub splines. Remove corrosion and apply only a very thin coat of grease -G 000 100- to input shaft splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.

3 -	Pressure plate

q	Removing and installing → Fig.

q	Check ends of diaphragm spring → Fig.

  Note

Pressure plates are protected against corrosion and greased. Clean contact surface only; otherwise the service life of the clutch will be considerably reduced.

4 -	M6 bolt, 13 Nm, M7 bolt, 20 Nm

q	Allocation → Electronic parts catalogue „ETKA“

q	Loosen or tighten diagonally in small steps

Centring clutch plate and removing and installing pressure plate –  Loosen or tighten bolts diagonally in stages. –  Reverse position of counterhold -3067- when removing.   Note Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Tighten bolts diagonally and evenly to prevent damage to the centring holes in the pressure plate housing and the centring pins in the flywheel.

Checking ends of diaphragm spring l  Wear up to half the thickness of the diaphragm spring is permitted.

04 Transmission