Clutch Disc: Service and Repair

Clutch, servicing, 01A, 5 SPD. M/T (AWD)

Special tools, testers and auxiliary items required:

^ Flywheel Retainer 3067
^ Centering mandrel 3176
^ Torque wrench V.A.G. 1331
(Transmission removed)

Note:
^ Replace clutch discs and pressure plates with damaged or loose rivets.
^ Allocate clutch discs and pressure plates according to Electronic Parts Catalog (ETKA) and engine code.
^ Clutch is depicted in conjunction with dual-mass flywheel.





1. Flywheel
^ Make sure centering pins are in place and seated correctly
^ Contact surface for clutch lining free of dirt, oil and grease
^ Install with white markings on flywheel - A - and pressure plate - B - pointing to each other (if present).

2. Clutch disc
^ Allocate according to Electronic Parts Catalog (ETKA)
^ Installation position at dual-mass flywheel: Clutch disc lining must make full contact with flywheel
^ Installation position at simple flywheel: Spring cage points to pressure plate
^ If present, the writing "transmission side" always points toward pressure plate and transmission.
^ Centering
^ Lightly lubricate splines

Note:
^ 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 input shaft splines. Then move clutch disc on input shaft back and forth until hub on shaft moves easily. Always remove excessively applied grease.

3. Pressure plate
^ Removing and installing
^ Checking ends of diaphragm spring
^ Check spring connection and rivet connections
^ Check wire ring
^ Install with white markings on flywheel - A - and pressure plate - B - pointing to each other (if present).

Note:
^ Pressure plates are protected against corrosion and greased. Only the contact surface may be cleaned, otherwise service life of clutch is significantly reduced.

4. Bolt, 25 Nm
^ Loosen and tighten in stages and in diagonal sequence

5. Needle bearing





Centering clutch plate and removing and installing pressure plate
^ Loosen and tighten bolts in stages and in diagonal sequence.
^ Move retainer when removing.
^ When installing, make sure that white markings (if present) of dual-mass flywheel - A - and of pressure plate - B - align.

Note:
^ Contact surface of pressure plate and clutch disc lining must make complete contact on flywheel. Tighten securing bolts uniformly in diagonal sequence so that pressure plate centering holes and flywheel centering pins are not damaged.





Checking ends of diaphragm spring
^ Wear up to half the thickness of the diaphragm spring is permitted.

Note:
^ Allocate clutch pressure plate and clutch disc via engine code according to Parts Catalog.





Checking spring connection and rivet connection
^ Check spring connections - arrows A - for damage and rivet connections - arrows B - for secure seating.

Note:
^ Pressure plates with sharply bent or broken spring connections as well as loose rivet connections must be replaced.





Checking wire ring
^ Check wire ring in pressure plate - arrow - for damage. Replace pressure plate with broken wire ring.