Clutch, Removing and Installing

Clutch, removing and installing, 02M/02Y, 5 & 6 Speed M/T, AWD





Special tools, testers and auxiliary items required
^ Flywheel Retainer 3067
^ Centering mandrel 3190 A
^ Centering pin T10097 for clutch plate with larger hub diameter
^ Grease for clutch plate splines G 000 100

Removing
- Remove transmission.
- Insert flywheel retainer 3067 to loosen bolts.

Unscrew pressure plate as follows to avoid distortion of pressure plate (will cause bucking when vehicles moves off):
- Remove all 6 bolts in sequence in a clockwise direction in steps of 90° (1/4 turn) until pressure plate is free.
- Remove pressure plate and clutch plate.

Installing
Installation is performed in reverse order of removal. Note the following:

Note:
^ Allocate pressure plate and clutch plate via engine code.
^ If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the transmission in order to reduce the smell of burnt linings.
^ Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Then move clutch plate on input shaft back and forth until hub on shaft moves easily.
Always remove excessively applied grease.
^ Pressure plates are protected against corrosion and greased. Only the contact surface may be cleaned, otherwise service life of clutch is significantly reduced.
^ Contact surface of pressure plate and clutch plate lining must make complete contact on flywheel. Only then insert mounting bolts.





- Note installation position of clutch plate:
^ The writing "Getriebeseite" or "Getr.-Seite" - arrow - points toward pressure plate and transmission.





- Change over flywheel retainer 3067 when installing.
- Use Centering Mandrel 3190 A to center clutch plate.





- Use Centering Pin T10097 to center clutch plate with larger hub diameter.

Install pressure plate as follows to avoid distortion of pressure plate (will cause bucking when vehicles moves off):
- Place pressure plate onto alignment pins.
- Screw in all 6 bolts uniformly by hand until bolt head makes contact on pressure plate.
- Tighten all 6 bolts in sequence in a clockwise direction in steps of 90° (1/4 turn) until housing makes contact on flywheel.
- Tighten all 6 bolts in sequence in a clockwise direction to final tightening torque.
- Install transmission.

Tightening torque