Removal and installation the clutch module
Remove the gearbox and secure it with strap "1" to the gearbox mount "T40173." To prevent oil leakage after removing the left shaft with flange, tilt the gearbox slightly backward. Loosen the bolts "arrow" of the left shaft with flange support.
Remove the shaft with the flange in the direction of arrow A from the gearbox. While doing this, hold the end of the shaft "2" in the center of the hole in the front final drive "arrow 3". Risk of damage to the shaft seal. If the shaft is not held centered during subsequent removal, the gear ring of shaft "2" will touch the shaft seal "arrow 3" between the differential and the gearbox housing. The damaged seal. replace the shaft seal.
If the left axle shaft with flange cannot be removed by hand, carefully remove the axle shaft with flange using a mounting tool. tool "VW 771". To do this, secure the plate of the removable device "T10037" on the axle shaft with the "arrow" flange and connect it to the spindle mounting. tool "VW 771" (nuts "A").
Secure the puller "T46176" 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 shaft 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 125 kW TDI engine)
Check the condition of the dual mass flywheel needle bearing. Needle bearings with every 4th "arrow" roller missing on a vehicle with a 4-cylinder TDI engine (except for the 125 kW TDI engine) are subject to replacement. New needle bearings have a full set of rollers. On all other vehicles, the absence of the fourth roller is not a defect of the needle bearing. Do not replace the needle bearing!
Installation
Installation in reverse order. Lubricate the clutch release bearing as specified. 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-.
Clean the drive shaft "arrow". Lubricate the drive shaft splines with a thin layer of clutch disc spline grease -G 000 100-. Before installing the clutch module, remove grease from the drive shaft journals "arrow" down to the spline. Carefully install the clutch module onto the drive shaft, ensuring it is not tilted. Unscrew the puller "T40176" from the clutch module. Rotate clutch module "1" so that the differential input "arrow 3" is visible. Insert the left shaft with flange into the gearbox in the direction of "arrow B", while inserting the end of shaft "2" in the center of the final drive shaft seal "arrow 3". Risk of damage to the shaft sealing lip. If the shaft is not held in the center, the gear engagement of shaft "2" can damage the seal ring. the "arrow 3" cuff between the final drive and the gearbox housing. Damaged seal. replace the shaft seal. Screw the shaft support with the "arrow" flange.
The original text of the material can be found on the website: AUDIMANUAL.ru