Warning: Separate characteristics are also given in the text of the Chapter and, if they are mandatory, are highlighted in bold.
Common parameters | |
Clutch | |
Type | Single disc dry with hydraulic drive |
Maximum disc runout | 0.5mm |
Drive shafts | |
Length | |
RKPP (02A) and AT (096) | |
Left drive shaft | 447.4 mm |
Right drive shaft | 681.5 mm |
RKPP (020) | |
Left drive shaft | 455.5 mm |
Right drive shaft | 691.5 mm |
Position of balance weights (measured from surface hinge to the surface of the load) | 524.0 - 526.0 mm |
Lubrication of hinges | |
Lubrication type | Grease AUDI G 000 603 |
External ball and tripod joint | |
Hinge AND 81 mm | |
General | 80 g |
Volume at the hinge | 40 g |
Volume in a protective case | 40 g |
Hinge AND 90 mm | |
General | 120 g |
Volume at the hinge | 80 g |
Volume in a protective case | 40 g |
Internal hinge - ball | |
Hinge 94 mm | |
General | 90 g |
Volume at the hinge | 40 g |
Volume in a protective case | 50 g |
Hinge 100 mm | |
General | 120 g |
Volume at the hinge | 50 g |
Volume in a protective case | 70 g |
Internal hinge - tripod | |
General | 180 g |
Front hinge volume | 90 g |
Volume on the reverse side of the hinge | 90 g |
When replacing the protective cover, the hinge, if necessary, supplement grease. | |
Tightening torques for threaded connections | |
Fastener tightening torques are also given in the text of the Chapter and on
some illustrations*. *Tightening torques in bold type are subject to exact compliance; Efforts not in bold are indicative only | |
Clutch | |
flywheel clutch | 20 Nm |
Clutch Slave Bolt | 25 Nm |
Clutch master cylinder on pedal block | 25 Nm |
Drive shafts | |
hub nut | |
hub nut | 265 Nm |
with pendant "plus" | 200 Nm loosen 1 turn, tighten 50 Nm +30° |
Mounting the drive shaft to the gearbox flange | |
M8 | 40 Nm |
M10 | 80 Nm |
Driven disc and clutch basket. Engine 1.8 l
- 1 - flywheel
The contact surface of the friction linings must not contain lubrication grooves. Make sure that the centering pins are securely fastened
- 2 - driven disk
Watch the installation position, the clip for the springs points towards the pressure plate.
Warning: Clean the splines of the input shaft of the manual transmission, the driven disk if the previous disk is installed and the splines of the hub. Remove rust. Coat the splines with a thin layer of MoS2 grease. Be sure to remove excess grease.
- 3 - pressure plate
- 4 - twelve-sided bolt, 20 Nm
Loosen and tighten smoothly crosswise.
Attention: For the version with dual-mass flywheel, hexagon socket screws are installed, tightening torque 13 Nm
Driven disc and clutch basket. Engines 1.6 l
- 1 - twelve-sided bolt, 20 Nm. Loosen and tighten smoothly crosswise.
- 2 - flywheel
The contact surface of the friction linings must not contain lubrication grooves. Attention: The installation depth of the TDC sensor must correspond to different sizes of flywheels. Therefore, two different, color-coded screw plugs are screwed into the clutch housing.
- 3 - clutch driven disc. Lubricate centering elements, splines with a thin layer of MoS2 grease.
- 4 - push rod. Lubricate around the guide bushing in the manual transmission input shaft.
- 5 - retaining ring
- 6 - clutch release disk. Lubricate the mating surface of the stem with a thin film of MoS2 grease (VW G 000 100).
- 7 - fastening bolt. Tightening torque: 60 Nm + 1/4 turn (90 °). Be sure to replace the bolts.
- 8 - intermediate plate
- 9 - pressure plate
Maximum internal deformation: 0.2 mm. A disc with damaged or loose rivets should be replaced.
Hydraulic clutch
- 1 - brake fluid reservoir
- 2 - follower hose
- 3 - master cylinder
- 4 - clamp
- 5 - clutch pedal
- 6 - nut, 25 Nm. Self-locking, be sure to replace.
- 7 - holder
- 8 - hydraulic pipeline
- 9 - support
- 10 - anther
- 11 - air removal fitting
- 12 - working cylinder
- 13 - collar bolt, 25 Nm
- 14 - RKPP
- 15 - locking bracket
- 16 - clamp
- 17 - hydraulic pipeline
- 18 - connection/plug connection
- 19 - round ring. Put on the pipeline connection, moistened with brake fluid
- 20 - locking bracket
The clutch when the gear is engaged disconnects the power connection between the engine and the manual transmission and provides, thanks to the frictional connection, a smooth transmission of torque to the chassis when starting off.
The clutch consists of a pressure plate, a driven plate, a clutch release bearing and a hydraulic drive.
The pressure plate is bolted to the flywheel. The flywheel, in turn, is connected to the crankshaft of the engine. Between the pressure plate and the flywheel is a driven disk, which is pressed against the flywheel by a pressure plate. The driven disk is connected to the manual transmission input shaft through a spline connection.
When you press the clutch pedal through the master cylinder located at the bottom of the car, pressurized fluid is transferred to the slave cylinder. The piston of the working cylinder, pressing the clutch release bearing, acts on the pressure plate. In this case, the driven disk is retracted from the flywheel. The power connection between the engine and the manual transmission is interrupted.
The clutch hydraulic system runs on brake fluid coming from a reservoir.
Each time the clutch is engaged and disengaged as a result of force action, the friction linings of the driven disk are worn. The driven disk is a wear part. However, its average service life is more than 100,000 km. Disc wear depends mainly on the load (trailer operation) and driving style. The clutch does not require maintenance, as it is self-adjusting.
Engines are usually equipped with a dual-mass flywheel. The dual-mass flywheel has a spring-damped system that helps reduce vibrations generated by the engine. It also reduces the noise level in the low speed range. The driven clutch disc in this case consists of a hub, a driven plate and friction linings. There are no torsion springs.
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