volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Repairing "Sachs” clutch > < Removing

Golf Mk5

Installing
Installing
Install in the reverse order of removal, observing the following:
  Note
t  Select clutch plate and pressure plate according to engine code and → Electronic Parts Catalogue (ETKA).
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.
   
Installation position of clutch plate
l  Lettering “Getriebeseite” and protruding spring cage face gearbox.
  A30-0132
Checking ends of diaphragm spring
l  Wear to half the thickness of the diaphragm spring -arrows- is permitted.
  V30-0094
Checking spring connections and riveted connections
–  Check spring connections between pressure plate and cover for cracks as well as rivet connections for secure seating.
l  A pressure plate with damaged spring connections or with loose rivet connections -arrows- must be renewed.
  Note
t  Renew clutch plates and pressure plates with damaged or loose rivet connections.
t  Select clutch plate and pressure plate according to engine code and → Electronic Parts Catalogue (ETKA)
t  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 splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.
t  Pressure plates are protected against corrosion and greased. Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.
t  Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert securing bolts.
  V30-0454
–  Reverse counterhold tool -3067- for installation.
–  Push pressure plate onto dowel pins.
–  Tighten all bolts evenly by hand until bolt heads contact pressure plate.
–  Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dual-mass flywheel → Item.
–  Install gearbox, Golf → Chapter.
–  Install gearbox, Passat → Chapter.
  N30-10000

Repairing "Sachs” clutch > < Removing