Warning: Clutch installation requires an AUDI-3176 centering mandrel or a common centering tool such as HAZET 2174.
Withdrawal
1. Remove the gearbox, refer to Section Removal and installation of the gearbox.
2. To prevent the flywheel from turning when the mounting bolts are loosened, fix the flywheel with a screwdriver and mandrel or AUDI-3067 tool.
Warning: The AUDI-3067 tool is shown in the accompanying illustration in the installation position, the tool must be turned over when removing.
3. Loosen the pressure plate fastening bolts criss-cross by 1 - 1.5 turns so as to unload the pressure plate.
Caution: If the bolts are completely loosened immediately, the pressure springs may be damaged.
4. After loosening the bolts, turn them out completely.
5. Take out pressure and conducted disks.
Caution: Do not drop the discs when removing, otherwise, after reinstalling, it may be difficult to disengage the clutch and jerk when it works.
6. Wipe the clutch release bearing without washing it.
7. Wipe the flywheel.
Examination
1. Check the pressure plate for signs of overheating and grooves.
2. Check the ends of the pressure springs (arrows on the accompanying illustration). Wear up to half of their thickness is allowed.
3. Check the spring connections between the pressure plate and the cover for cracks. Check the reliability of the riveted connections. If the rivets are loosened, the clutch must be replaced.
4. Check adjacent surfaces for cracks, overheating and wear. Pressure plates with an inward deflection of up to 0.2 mm can be used further. Checking is carried out using a ruler and a set of probes.
5. Check the flywheel for signs of overheating and grooves.
6. An oily disc and a disc that has mechanical damage should be replaced.
7. Check the thickness of the friction linings.
8. At the service station, you can check the end runout of the disc. It should not exceed 0.8 mm (at a distance of 2.5 mm from the edge).
Caution: This check is only done on an old disc that made it difficult to disengage the clutch. If necessary, carefully straighten the disc.
9. Check the disc in the installed position by hand. To do this, lightly squeeze the bearing by hand and turn. The bearing should rotate easily.
Caution: For clutch release bearings with a plastic ring, the latter may come loose when removing the gearbox or the bearing itself. This is not a reason to replace the bearing.
10. Before installing the gearbox, glue the detached ring to the bearing ring with AMW 195 KD 01 glue. In this case, 3 spouts of the plastic ring (arrows on the accompanying illustration) must fit into the grooves of the bearing ring.
Warning: If the working surface of the plastic ring is worn more than 0.5 mm, the clutch release bearing must be replaced
11. When the car is moving, a damaged clutch release bearing makes noise when the clutch pedal is pressed. In this case, the bearing must be replaced.
Installation
Caution: Check the catalog for new parts. If used parts are installed, they must first be checked.
Warning: If the old clutch disc is burnt due to overloading, the pressure plate, flywheel and engine side of the transmission must be thoroughly cleaned to eliminate the smell.
1. Before installing a new pressure plate, remove the protective anti-corrosion grease only on its working surface. In other places, do not remove the grease in any case, because. this can result in a significant reduction in clutch life.
2. Check that the centering mandrel is securely installed on the flywheel.
3. Clean the driven disc splines from rust. Lubricate the input shaft teeth with a thin layer of MoS2 grease. Service stations use AUDI-G000100 grease for this. After that, move the driven disk in different directions on the input shaft so that the hub easily moves along the shaft. Be sure to remove excess grease.
4. When installing the driven disk, make sure that the helical spring package or the inscription «Getriebeseite» («Checkpoint side») turned towards the checkpoint. The friction linings must be in contact with the flywheel. If there are color marks, make sure that the white dots on the dual-mass flywheel (A) and pressure disc (IN) were opposite each other, refer to the illustration Flywheel, basket and clutch disc.
5. Center the driven plate on the pressure plate using a mandrel, such as HAZET 2174 or AUDI-3176. If the driven disk is not centered, it will not be possible to insert the input shaft later.
6. Install the pressure plate on the dowel pins on the flywheel.
Caution: The pressure plate must be in full contact with the flywheel. Only then insert the mounting bolts. Never tighten the pressure plate with bolts, otherwise the centering pins and their holes may be damaged.
7. Tighten the pressure plate mounting bolts 1–1.5 turns crosswise. Then tighten the bolts to the torque 25 Nm. In this case, the pressure plate should not warp, because. otherwise, the centering pins and their holes may be damaged.
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