1. Clutch module.
2. Shaft seal: for dual mass flywheel.
3. Needle bearing: for dual mass flywheel; check and replace if necessary. If the drive shaft is damaged, always replace the needle bearing. Depending on the design, needle bearings may have a full complement of rollers or needle bearings with every fourth roller missing. This is not a defect in the needle bearing.
4. Dual mass flywheel: with transfer plate; make sure that the centering pins are securely installed; there should be no grooves, oil or grease on the mating surface of the clutch lining.
5. Clutch driven disc: can only be replaced together with the pressure plate; mounting position: the clutch disc lining must be in contact with the flywheel, marking "Getriebeseite" (if available) must be facing the pressure plate or the gearbox.
6. SAC support plate: 2 clutch disc is integrated into the pressure plate; can only be replaced together with the clutch disc; check the ends of the membrane spring; check the pressure plate for warpage; check springs and riveted joints; there should be no grooves, oil or grease on the mating surface of the clutch lining.
7. Bolt: 22 Nm and turn 90° further; always subject to replacement; for fastening the pressure plate on the dual mass flywheel; loosen or tighten according to installation instructions.
Removal and installation the clutch pressure plate and clutch disc of a dual-disc clutch
Remove the clutch module.
1. Clutch pressure plate.
Risk of damage to the pressure plate and dual mass flywheel. Pressure plate "1" may only be removed and installed in a pre-compressed state. Pre-compressed pressure plates are deformed when bolts "2" are loosened or tightened, which leads to jerking when starting off. To compress pressure plate "1" using a hydraulic press, dual-mass flywheel "3" may only be supported by the sliding washer "arrow A." Supporting the dual-mass flywheel against the transfer plate "arrow B" will damage it (deformation). In this case, it is necessary to replace the dual mass flywheel. Install the clutch module so that the pressure plate "VW 510" is adjacent to the sliding washer "arrow A" in the dual mass flywheel. Install mont. device "T10254/3" on the spring tongues of the pressure plate "1" and press on them using a press. Compression stroke - dimension "x" 8...9 mm. Unscrew all 6 bolts "2" and release the press. Remove pressure plate "1" and clutch driven disc.
Installation
Installation in reverse order. Risk of damage to clutch disc "1" and pressure plate "2". The teeth "arrow A" of clutch disc "1" must fit into the recesses "arrow B". When pressure plate "2" is properly installed, the centering pins "arrow C" must be flush with the pressure plate.
Center clutch disc "1" using centering mandrel "T40171". Clutch disc installation position: toothed washer "arrow A" should face pressure plate "2". Install pressure plate "2" onto centering pins "Arrow C". Centering pins "arrow C" should be flush with the pressure plate. To compress pressure plate "1" using a hydraulic press, dual-mass flywheel "3" may only be supported by the sliding washer "arrow A." Supporting the dual-mass flywheel against the transfer plate "arrow B" will damage it (deformation). In this case, it is necessary to replace the dual mass flywheel.
Install the clutch module so that the pressure plate "VW 510" is adjacent to the sliding washer "arrow A" in the dual mass flywheel. Install mont. device "T10254/3" over the centering mandrel "T40171". Apply pressure with the press until the pressure plate "1" lies against the dual-mass flywheel "3" "arrows C". Screw in all 6 bolts "2" one after the other and tighten to the specified torque. Release the pressure from the press. Install the clutch module.
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