Volkswagen Workshop Service and Repair Manuals

Repairing 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-

l	Remove gearbox.

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 on dual-mass flywheel → Fig.

q	Installation position with one-piece flywheel: spring cage faces the pressure plate.

q	Centring → 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 -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..

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 and in steps

Centring clutch plate and removing and installing pressure plate –  Loosen or tighten bolts diagonally in stages. –  Reverse position of counterhold -3067- when removing.   Note Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Tighten bolts diagonally and evenly to prevent damage to the centring holes in the pressure plate housing and the centring pins in the flywheel.

Installation position of clutch plate in conjunction with dual-mass flywheel l  Lettering „Getriebeseite“ (gearbox side) faces gearbox.

Checking ends of diaphragm spring l  Wear up to half the thickness of the diaphragm spring 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. l  A pressure plate with damaged spring connections or with loose rivet connections -arrows- must be renewed.