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Gearbox mechanics,operation, construction,diff. > < Repairing clutch release mechanism

Polo Mk5

Repairing clutch
   
Repairing clutch
Special tools and workshop equipment required
t  Counterhold -3067-
t  Torque wrench -V.A.G 1331-
t  Additionally required for vehicles with a petrol engine: centring drift -T10086-
t  Additionally required for vehicles with a diesel engine and with turbo diesel engine: centring drift -3190 A-
t  Grease for clutch plate splines -G 000 100-
t  Allocate grease using → Electronic parts catalogue (ETKA).

l  Remove gearbox.
   
  Note
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: spring cage faces pressure plate.
q   Centring on vehicles with a petrol engine → Fig..
q   Centring on vehicles with diesel engine and with turbo diesel engine → Fig.
q   Lightly grease splines
  Note
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 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 on vehicles with petrol engine → Fig..
q   Removing and installing on vehicles with diesel engine and with turbo diesel engine → Fig.
q   Check ends of diaphragm spring → Fig.
  Note
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   Determine according to → Electronic parts catalogue (ETKA).
q   Loosen or tighten diagonally and in steps

Vehicles with petrol engine
   
Centring clutch plate and removing and installing pressure plate
–  Loosen or tighten bolts diagonally in stages.
–  Reverse position of counterhold -3067- when removing.
  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.
Vehicles with diesel engine and with turbo diesel engine.
  A30-0069
Centring clutch plate and removing and installing pressure plate
–  Loosen or tighten bolts diagonally in stages.
–  Reverse position of counterhold -3067- when removing.
  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.
  V30-0378
Checking ends of diaphragm spring
l  Wear up to half the thickness of the diaphragm spring is permitted.
  V30-0094

Gearbox mechanics,operation, construction,diff. > < Repairing clutch release mechanism