Table of contents: Hydraulic clutch system ↓ Removal and installation the clutch… ↓
Hydraulic clutch system
Take into account the instructions for removing and installing the main and working cylinders. clutch.
1. Clutch slave cylinder: Do not operate after removing the clutch pedal; after working on the hydraulic clutch drive, bleed the clutch drive; brake impact. liquids on the gearbox are not allowed.
2. Air bleed screw: 5.5 Nm; follow the procedure when pumping; a broken bleed nipple can be unscrewed with an internal hex key (3 mm).
3. Protective cap.
4. Nozzle.
5. Pipe-hose line of nipple connectors on the main and working cylinders, with a frequency modulator.
6. Retaining clamp.
7. Sealing ring: replace if damaged; install by wetting the brake. liquid.
8. Main cylinder feed hose. clutches with built-in seals. nozzles; in case of damaged seals. replace the feed hose on the nozzles.
9. Brake fluid reservoir. liquid.
10. Locking clamp: To remove and install the hose line, pull it out until it stops.
11. Clutch master cylinder: after working on the hydraulic clutch drive, bleed the clutch drive.
12. Pipeline.
13. Holder: for pipeline; is attached to the control gear.
14. Bolt: 20 Nm.
15. Sealing ring: replace if damaged; install by wetting the brake. liquid.
16. Locking clamp: To remove and install the hose line, pull it out until it stops.
17. Bolt: 20 Nm; clutch slave cylinder to gearbox.
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.
Pull the shaft with flange out of the gearbox in the "direction of arrow A". In doing so, hold the shaft end "2" centered in the hole in the front final drive "arrow 3". If the shaft is not held centered during subsequent removal, the shaft gear ring "2" will hit the shaft seal "arrow 3" between the differential and the gearbox housing. 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 "VW771". 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 "T40176" to the clutch module "A" with the nut "B" "arrow".
Rotate the T40176 puller upward. 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".
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. Carefully place the clutch module with the pressure plate facing downwards on the workbench.
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 the flange into the gearbox in the direction of "arrow B", while inserting the end of shaft "2" into the center of the final drive shaft seal "arrow 3". If the shaft is not held centered, 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 left shaft support with the "arrow" flange.