Table of contents: Clutch module ↓ Removal and installation the clutch… ↓
Clutch module
A. Locking pin: not available on all vehicles; when connecting the clutch module "2" to the driven disk "1" the locking pin "A" (if available) should fit into hole "B"
B. Locking hole: when connecting clutch module "2" to driven disc "1", locking pin "A" (if available) should fit into hole "B"
Caution! The clutch may malfunction if installed incorrectly. If the driven disc "A" retaining pins are not in the clutch module "B" hole, serious clutch failure may occur.
1. Driven disc: in 4-cylinder engines. 3 holes with threaded bushings; in 6-cylinder engines. 6 holes with threaded bushings; with needle bearing.
2. Clutch module: with transfer plate; parts: dual mass flywheel, clutch disc and clutch pressure plate.
3. Bolt: 60 Nm; for mounting a dual-mass flywheel on the driven disk; 3 pcs. in 4-cylinder engines; 6 pcs. in 6-cylinder engines; always subject to replacement; observe the sequence. puffs.
Sequence for tightening the clutch module to the flywheel disc (4-cylinder engine)
Use new bolts. Tighten the bolts with a 16 mm ring spanner "VAG 1332/14". To engage the gear, remove the shift shaft "1" and shift the gearbox lever "2" forward in the "direction of the arrow".
The next stage of work is absolutely necessary to ensure uniform contact with the driven disk without distortion. Rotate both front wheels in the same direction until the clutch module completes one full rotation (360°). The inspection hole marked "arrow" should again be visible in the recess in the gearbox housing.
Tighten the first bolt "arrow" by hand (2 Nm). Rotate the clutch module 120° in the direction of engine rotation using the front wheels and tighten the second bolt also by hand (2 Nm). Rotate the clutch module again 120° in the direction of engine rotation. Now screw in the 3rd bolt and tighten it to the specified tightening torque. Now tighten the 2 remaining bolts to the specified torque.
Clutch repair
Note: Before working on the clutch, remove the transmission. To avoid damaging the SAC pressure plate, follow the instructions for working with the SAC pressure plate during removal and installation. In vehicles with a clutch pressure plate (manufacturer LuK) when replacing only the clutch disc, it is necessary to adjust the position of the adjusting ring. Check the clutch pressure plate for deformation. Replace the clutch disc/pressure plate with damaged or loose rivets. Select the clutch disc and pressure plate according to the engine letter designation. The pressure plates are protected against corrosion and lubricated with grease. Do not clean the clutch pressure plate, except for the friction surface of the clutch disc. Otherwise, the clutch life will be significantly reduced. The friction surface of the clutch pressure plate and dual mass flywheel must be thoroughly cleaned (degrease). To reduce the smell of burnt clutch, thoroughly clean the gearbox housing in the clutch area and the engine on the gearbox side. If there is visible damage to the drive shaft surface in the area of the needle bearing of the dual-mass flywheel "arrow", the drive shaft and the needle bearing of the dual-mass flywheel must be replaced.
Check the primary shaft at the installation location in the driven disk "arrow" for signs of running-in. If necessary, replace the driven disk needle bearing. Clean the gear connection of the input shaft and, if using a clutch disc, the gear connection of the hub, remove corrosion and apply a very thin layer of grease for the gear connection of the clutch disc -G 000100- to the gear connection. Then move the clutch disc on the drive shaft in both directions until the hub moves easily on the shaft. Be sure to remove excess grease. Remove grease from the drive shaft journals down to the splines.
Check the wear of the plastic disc "A" of the dual-mass flywheel "Sachs manufacturer". Check the condition of the dual-mass flywheel needle bearing "arrow" and replace if necessary.
Lack of lubrication in the support areas of the clutch release bearing "arrow" can lead to a cracking sound when the clutch is engaged. Apply a sufficient amount of solid lubricant -G 000150- to the bearings of the clutch release bearing "arrows".
Do not install the clutch module on the transfer plate "arrow" on one side only. This can cause the transfer plate to become warped, leading to operational problems.
Removal and installation the clutch module
Remove the gearbox and secure it with strap "1" to the gearbox mount "T40173." To prevent transmission oil leakage after removing the left shaft with flange, tilt the gearbox back slightly.
Remove the left shaft with flange.
Secure the puller "T40176" to the clutch module "A" with the nut "B" "arrow".
Turn the puller "T40176" upwards. Risk of damage to the seal. the seal and needle bearing in the dual-mass flywheel! To prevent the clutch module from tipping over, hold the bottom of the clutch module as shown in the figure. When removing and installing the clutch module, ensure that the seals and needle bearing in the dual mass flywheel "arrow" are not damaged. Damaged radial shaft seals and needle bearings must be replaced. Remove the clutch module without tilting it from the drive shaft "arrow".
Risk of damage to the dual mass flywheel transfer plate! Do not install the clutch module on the transfer plate "arrow" on only one side. This can cause the transfer plate to become warped, leading to operational problems. Carefully place the clutch module with the pressure plate facing downwards, for example on a workbench.
Vehicles with 4-cyl. TDI engine (except for the TD1125 kW engine)
Check the condition of the dual mass flywheel needle bearing. Needle bearings where every 4th "arrow" roller is missing must be replaced. New needle bearings have a full set of rollers. On all other vehicles, the absence of the 4th roller is not a defect of the needle bearing. Do not replace the needle bearing!
Installation
Installation in reverse order. Thoroughly clean the left half-shaft with flange, the gearbox housing in the differential access area "arrow A" and the shaft sealing ring "arrow B". If the shaft sealing ring between the differential and the gearbox housing "arrow B" is damaged, replace it. Fill the space between the working edge and the boot "arrow B" halfway with consistent grease -G 052 128 A1-.
Lubricate the release bearing as prescribed. Clean the splines and journals of the input shaft "arrow". Lubricate the drive shaft splines with a thin layer of spline grease for clutch driven discs -G 000 100-. Before installing the clutch module, wipe the drive shaft journals "arrow" up to the spline. Carefully, without tilting, install the clutch module on the drive shaft. Unscrew the puller "T40176" from the clutch module. Install the left shaft with flange.