Volkswagen Workshop Service and Repair Manuals

Removing and installing „Sachs“ clutch

Special tools and workshop equipment required

t	Counterhold -3067-

t	Centring mandrel -3190 A-

t	Torque wrench -V.A.G 1331-

t	Grease for clutch plate splines -G 000 100-

Removing l  Remove gearbox. –  Use counterhold -3067- to loosen bolts.

–  Loosen bolts in small steps and diagonally. l  As bolts are removed, stop -2- with pin -1- must loosen. –  If stop does not loosen, press pin towards dual-mass flywheel. –  Remove pressure plate and clutch plate. Installing Install in the reverse order of removal, observing the following:   Note t  Renew pressure plate and clutch plate together only. 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“ (gearbox side) faces gearbox.

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

Checking spring connections and riveted connections –  Check spring connections between pressure plate and cover for cracks as well as rivet connections for secure seating.

–  Reverse counterhold tool -3067- for installation.

Install pressure plate as follows so it is not deformed during installation (leads to jolts when moving off): –  Make sure that stop pin (position setter) -arrow- can be moved easily. l  Stop pin -arrow- must lift off pressure plate when this is done. –  Push pressure plate onto dowel pins. –  To centre clutch plate, use centring mandrel -3190 A-. –  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. Torque setting → Item l  Install gearbox.