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Volkswagen Workshop Service and Repair Manuals

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Repairing Sachs clutch > < Removing

Golf Mk5

Installing
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.
  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.
  Note
t  Renew clutch plates and pressure plates with damaged or loose rivet connections.
t  Always renew pressure plate and clutch plate together.
t  Select clutch plate and pressure plate according to engine code and → Electronic Parts Catalogue (ETKA).
t  If clutch has burnt out, thoroughly clean clutch housing, flywheel and parts of engine facing gearbox to reduce smell of burnt linings.
t  Clean input shaft splines and, on used clutch plates, clean hub splines; remove corrosion and apply only a very thin coat of clutch plate spline 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.
–  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 → Item.
–  Install gearbox, Golf → Chapter.
–  Install gearbox, Passat → Chapter.
  V30-0378

Repairing Sachs clutch > < Removing