Clutch (LuK), Removing and Installing

Clutch (LuK), removing and installing - 0A4, 5 Speed M/T

Removing
- Remove transmission.
- Insert flywheel retainer 3067 to loosen bolts.
- Loosen bolts in small stages in diagonal sequence.
- Remove pressure plate and clutch plate.

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

Note:
^ Only replace the pressure plate and clutch plate together. Allocate pressure plate and clutch plate according to engine code.
^ Only check and, if necessary, rest self-adjusting pressure plate adjusting ring on new LuK clutches.
^ Make sure centering sleeves for engine to transmission are installed in cylinder block, install if necessary.
^ If centering sleeves are not present, shifting difficulties, clutch problems and possibly noise in transmission (loose gear rattling) will occur.





Installation position of clutch plate
^ Marking "Getriebeseite" (transmission side) faces toward transmission.





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





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

Note:
^ Replace clutch plates and pressure plates with damaged or loose rivets.
^ To reduce odor caused by a burnt clutch, thoroughly clean the clutch bell housing, the flywheel and the side of the engine facing toward the transmission.
^ 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 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. Only the contact surfaces may be cleaned, otherwise the service life of the clutch will be considerably reduced.
^ The pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then may the securing bolts be installed.





- Reposition flywheel retainer 3067 for installation.
- Position pressure plate on alignment pins.
- To center clutch plate, use centering pin 3190 A.
- Screw in all bolts uniformly by hand until bolt head makes contact on thrust plate.
- Tighten bolts in small stages in diagonal sequence in order to prevent damage to centering holes of pressure plate and centering pins of dual mass flywheel.
- Install transmission.