Golf Mk5
| Repairing clutch, in conjunction with one-piece flywheel |
| Special tools and workshop equipment required |
| t | Counterhold -3067- |
| t | Torque wrench -V.A.G 1331- |
| t | Grease for clutch plate splines -G 000 100- |
| t | Centring mandrel -T10097- |
| l | Remove gearbox. |
Note| t | Renew clutch plates and pressure plates with damaged or loose rivets. |
| t | Select clutch plate and pressure plate according to → Electronic parts catalogue (ETKA) and engine code. |
| 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. |
| 1 - | Flywheel |
| q | Removing and installing → Rep. gr.13 |
| q | Ensure that centring pins fit tightly |
| q | Keep contact surface for clutch lining free of grooves, oil and grease. |
| 2 - | Clutch plate |
| q | Allocation → 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 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. |
| q | Check spring connections and riveted connections → 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 | Determine according to → Electronic parts catalogue (ETKA). |
| q | Loosen or tighten diagonally and in steps |
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