volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Gearbox mechanics,operation, construction,diff. > < Repairing clutch release mechanism

Golf Mk4

Repairing clutch
   
Repairing clutch
Special tools and workshop equipment required
t  Counterhold tool -3067-
t  Centring mandrel -T10097-
t  Torque wrench -V.A.G 1331-
t  Grease -G 000 100-

(Gearbox removed)
  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 gear, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.
t  Replace clutch plates and pressure plates having 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
Allocation → Electronic parts catalogue (ETKA)
q   Installation position on dual-mass flywheel → Fig.
q   Installation position with single piece flywheel: 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 the 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 - Bolt
q   Allocation → Electronic parts catalogue (ETKA)
q   On dual-mass flywheel
q   22 Nm
q   Always renew
q   On single-piece flywheel
q   20 Nm
q   Loosen or tighten diagonally and in steps

   
Clutch plate installation position on dual-mass flywheel
l  The text „Getriebeseite“ (gearbox side) or „Getr.-Seite“-arrow- always faces pressure plate and gearbox.
  A30-0132
Centring clutch plate and removing and installing pressure plate
–  Loosen or tighten bolts diagonally in stages.
–  Reverse position of counterhold tool -3067- when removing.
  Note
t  Pressure plate contact surface and clutch plate lining must make full contact with flywheel.
t  Tighten securing bolts diagonally and evenly to prevent damage to pressure plate centring hole and flywheel centring pins.
  N30-0345
Check ends of diaphragm spring
l  Wear up to half the thickness of the diaphragm spring is permitted.
  V30-0094

Gearbox mechanics,operation, construction,diff. > < Repairing clutch release mechanism