Withdrawal
1. Remove a transmission, the corresponding chapter see.
2. Mark the position of the pressure plate on the flywheel with a marker or paint.
3. Stop the flywheel with a large screwdriver or punch, inserting it into the ring gear of the flywheel to keep it from turning when unscrewing the bolts securing the pressure plate to it. In workshops, a special AUDI-3067 shoe is used for this, which is mounted on the flywheel ring gear.
Attention! To center the clutch disc when installing the clutch disc, an AUDI-3176 roller or a non-working primary shaft is used.
4. Loosen the pressure plate bolts in increments of one to one and a half turns, working in a criss-cross pattern, until the bolts can be unscrewed by hand.
Attention! If the bolts are completely unscrewed immediately, the diaphragm spring may be damaged.
5. Remove the pressure and driven discs.
Attention! When performing this operation, do not drop the discs, otherwise jerking and difficulty with clutch separation may occur after assembly.
6. Wipe the release bearing. The bearing must not be flushed.
7. Wipe the flywheel with a rag.
Examination
8. Check the pressure plate for burnout cracks and grooves.
9. Check the condition of the segments (see arrows in illustration) diaphragm spring. Abrasion of segments up to half of their thickness is allowed.
10. Check diaphragm spring segments for cracks, rivet strength and seating. Replace the disc with damaged or loose rivets.
11. Check up a basic surface of a pressure disk on absence of cracks, traces of a burn and wear. Discs with an inward deflection of up to 0.2 mm can still be installed. Check with a ruler and measuring template.
12. Check up a flywheel condition. Make sure there are no burn marks or ripples.
13. Replace clutch discs with oily surfaces or mechanical damage.
14. Check the thickness of the friction lining of the clutch disc with a vernier caliper and make sure there are no cracks in the lining.
In the workshop, the clutch disc can be checked for runout. Lateral runout of the driven disc must not exceed 0.8 mm or 2.5 mm from the outer edge. Attention! This check is necessary only if the previous driven disk is installed, and the clutch was not disengaged before it was dismantled. If necessary, the disc can be carefully straightened.
15. Check the release bearing stroke without removing it. The bearing must rotate easily, otherwise replace it. While driving, a faulty bearing manifests itself as noise when the clutch pedal is depressed. In this case, the bearing must be replaced.
Attention! A release bearing with a plastic ring can be installed. When removing the gearbox, this plastic ring may come off. In this case, the bearing does not need to be changed. Lubricate the detached ring before installing * the gearbox with AMV 195KD101 glue and glue it to the outer ring. At the same time, three protrusions on the plastic ring (see arrows in illustration 2.15) must fit into the recesses on the outer ring. If the plastic ring of the release bearing is worn by more than 0.5 mm, the release bearing must be replaced.
2.15. At the same time, three protrusions on the plastic ring (si. arrows', must go into the recesses on the outer ring
Installation
Attention! When installing new clutch pressure and clutch discs, follow the engine code and series to avoid installing inappropriate parts. To do this, be sure to check in the spare parts catalog whether the available pressure plate and clutch disc are suitable for this engine.
If the old clutch parts are installed, then their condition should be checked first.
Attention! If the previous driven disk is burned due to overloads, then in order to avoid the appearance of an unpleasant odor in the future, before installing the clutch, thoroughly clean the clutch disks, as well as the side of the flywheel facing the gearbox, and engine parts near the gearbox.
16. Remove anti-corrosion grease before installing a new pressure plate only from its active surface. In other places, do not remove the grease in any case, otherwise the clutch life will be significantly reduced.
17. Check up reliability of landing of aligning fingers of a flywheel.
18. Clean off corrosion and apply a thin layer of molybdenum grease to the splines of the hub of the driven disk, as well as to the gear rim of the input shaft of the gearbox. After that, move the clutch disc on the input shaft back and forth until the drive disc hub on the shaft moves easily. Be sure to remove excess grease. 19 Fit the clutch disc, making sure that the vibration damper springs point towards the pressure plate. The friction lining must be in contact with the flywheel. Some discs are labeled «Getriebeseite» (the side that should face the gearbox).
20. Center the position of the driven plate on the pressure plate using a suitable shaft, such as AUDI-3176 or HAZET-2174. If the driven plate is not installed in the center of the pressure plate, then it will not be possible to start and install the gearbox input shaft later. As an aid for centering, you can use a non-working input shaft of the gearbox.
21. Install the pressure plate on the appropriate mounting pins on the flywheel.
Attention! The pressure plate must lie completely against the flywheel, without distortion. Do not tilt the pressure plate as this will damage the seat pins and centering holes. Only after centering the disc, insert the fixing bolts. Never tighten the disc with bolts, otherwise the centering pins will be damaged.
Attention! After installing a new clutch disc with the old pressure plate with an adjusting ring, this ring should be moved back to the stop. Otherwise, the pressure plate will act with reduced force, which will cause accelerated clutch wear.
If the driven disk has not changed, then the adjusting ring does not need to be retracted.
22. Insert bolts And fastenings of a pressure disk into openings and screw them approximately on 1/3 turns. Screw nuts B onto the bolts and tighten them only slightly (see illustration).
2.22. Insert bolts A of the pressure plate into the holes, screw them in about ⅓ of a turn and screw on the nuts
23. Place the pressure plate on the press so that only the heads of the bolts are in contact with the press plate (see arrows in illustration), and insert a centering roller, e.g. 3062, into the disc hole.
2.23 Place the pressure plate on the press so that only the heads of the bolts are in contact with the press plate (see arrows), and insert a centering roller into the disc hole
Attention! When performing the following steps, do not perform them «power» method. Otherwise, the forks of the adjusting ring will be broken.
24. Press the centering roller and disc with a press so that the adjusting ring starts to move and at this moment, use two screwdrivers to move the ring in the direction of the arrows in the illustration until it stops.
2.24. Move the adjusting ring in the direction of the arrows in the illustration until it stops
25. Hold the adjusting ring in this position and slowly release the press pressure on the disc so that the ring does not move.
26. Insert the pressure plate mounting bolts and tighten them by hand, and then tighten them 1-1½ turns in a cross pattern until the pressure plate mounting bolts are tightened to the required torque. The tightening torque for the bolts is 25 Nm. The pressure plate must not be skewed, otherwise the locating pins and holes for the centering pins will be damaged
27. Remove the driven disc centering tool.
28. Install the gearbox.
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