Clutch, LuK

Clutch, LuK

Special tools, testers and auxiliary items required

• Flywheel Retainer (3067)

• Centering Mandrel (T10097)

• Grease for Clutch Disc Shaft Splines (G 000 100)

Removing

• Transmission removed. Refer to => [ Transmission, Installing ] Transmission, Installing.

- Insert (3067) to loosen bolts.






When removing, loosen the bolts as follows, so that the pressure plate does not distort (causing shuddering on acceleration):

- Loosen all 6 bolts clockwise, one after the other and in steps of 90° (1/4 turn) until the pressure plate is free.

- Remove the pressure plate and the clutch plate.

Installing

Install in reverse sequence; note the following points:

• Dual-mass flywheel, pressure plate and clutch plate are allocated to each other and must not be mixed with other manufacturer's components.

• Always replace the clutch and pressure plates together and allocate them according to the engine code.

• Check the adjusting position on a new pressure plate.

• To reduce odor caused by a burnt clutch, thoroughly clean the clutch housing, the flywheel and the side of the engine facing toward the transmission.

• Clean the input shaft splines and on a used clutch plate, the hub splines, remove corrosion and apply only a very thin coating of grease (G 000 100) onto the splines. Then move clutch plate back and forth on input shaft until the hub moves freely on the shaft. Excess grease must be removed.

• Pressure plates are corrosion-protected and greased. The pressure plate may not be cleaned, with the exception of the friction surface on the clutch plate. Otherwise the service life of the clutch will be greatly reduced.

• The friction surfaces on the pressure plate and the dual mass flywheel must be cleaned thoroughly. There must be no grease.

• The pressure plate contact surface and clutch plate lining must make full contact with the flywheel. Only then may the securing bolts be installed.

• Make sure centering sleeves for engine to transmission are installed in cylinder block, install if necessary.

• If alignment sleeves are not installed, difficulty in shifting, clutch problems and possibly noises from the transmission (loose gear chatter) may develop.

Checking Ends of the Diaphragm Spring





• Wear up to half the thickness of the diaphragm spring - arrows - is permitted.

Check Spring Connections and Rivet Connections





- Check the spring connections - arrows A - for damage and the rivet connections - arrows B - for secure fit.

• A pressure plate with severely kinked or broken spring connections or with loose rivet connections must be replaced.

Checking the Adjustment Mechanism Position Only on New Sac Pressure Plates





• Both edges - A - of the adjusting ring must be located between both notches - B arrows -.

• If the adjusting ring takes on a different position with new pressure plates, pressure plate and clutch plate must not be installed.

• With used clutches, the adjusting ring may take on a position outside of the notches.

Installation Position of Clutch Plate





• Marking "Getriebeseite" (transmission side) faces toward transmission.

- Insert (3067).






- Position the pressure plate on the alignment pins.

- To center the clutch plate, use the (T10097).

When installing, tighten bolts as follows so pressure plate does not distort (causing shuddering on acceleration):

- Screw in all 6 bolts evenly, by hand, until the bolt heads contact the pressure plate.

- Tighten all 6 bolts clockwise, one after the other and in steps of 90° (1/4 turn) until the housing contacts the flywheel.

- Tighten all 6 bolts clockwise, one after the other to tightening specification. Tightening specification - item 4 - => [ (Item 4) Bolt ] Clutch, LuK Overview.

- Install transmission. Refer to => [ Transmission, Installing ] Transmission, Installing.