Volkswagen Workshop Service and Repair Manuals

Repairing clutch

Special tools and workshop equipment required

t	Counterhold -3067-

t	Torque wrench -V.A.G 1331-

t	Centring mandrel -3190 A-

t	For engines having a crankshaft of smaller diameter or having needle bearings in the crankshaft - → Fig.centring mandrel -T10086-

t	Grease for clutch plate splines -G 000 100-

l  Remove gearbox

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.

t	Renew clutch plates and pressure plates with 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 with two-part flywheel: shorter end of hub faces pressure plate

q	Text „Getriebeseite“ (gearbox side) always faces pressure plate and gearbox

q	Installation position with single piece flywheel: spring cage faces pressure plate

q	Centring → Fig.

q	Centring for engines having a crankshaft of smaller diameter or having needle bearings in the crankshaft - → Fig.

q	Lightly grease splines

Clean input shaft splines and, on used clutch plates, hub splines; remove corrosion and apply only a very thin coat of grease for clutch plate splines -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	Removing and installing for engines having a crankshaft of smaller diameter or having needle bearings in the crankshaft - → Fig.

q	Check ends of diaphragm spring → Fig.

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	Allocation → Electronic parts catalogue „ETKA“

q	Loosen or tighten diagonally in small steps

Centring clutch plate and removing and installing pressure plate –  Loosen or tighten bolts diagonally in stages. –  Reverse position of counterhold -3067- when removing.

For engines having a crankshaft of smaller diameter -arrow- or having an needle bearing -arrow- in the crankshaft

Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing -arrow- in the crankshaft –  Loosen or tighten bolts diagonally in stages. –  Reverse position of counterhold -3067- when removing. Continuation for all   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.

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