Clutch, Sachs

Clutch, Sachs - 0A4, 5 Speed M/T

Special tools, testers and auxiliary items required
^ Retainer 3067
^ Centering mandrel 3190 A
^ Torque wrench V.A.G 1331
^ Grease for clutch disc shaft splines G 000 100

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





- Loosen bolts in small stages in diagonal sequence.

^ When removing, stop -2- must loosen together with pin -1-.

- If stop does not loosen: Press pin in direction of dual mass flywheel.
- Remove the pressure plate and the clutch plate.

Installing
Install in reverse sequence; note the following points:

Note:
^ Only replace the pressure plate and clutch plate together. Allocate pressure plate and clutch plate according to engine code.
^ 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.





Installation Position of Clutch Plate
^ Marking "Getriebeseite" (transmission side) faces toward transmission.





Checking Ends of The Diaphragm Spring
^ Wear up to half the thickness of the diaphragm spring -arrows- is permitted.





Checking Spring Connections and Rivet Connections
- Check spring connections between pressure plate and cover for cracks, and check rivet connections for secure fit.

Note:
^ Replace clutch plates and pressure plates with damaged or loose rivets.
^ Always replace the clutch plate and pressure plate together.
^ Allocate clutch disc and thrust plate via engine code.
^ 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 the flywheel retainer 3067 for installation.
- Position the pressure plate on the alignment pins.
- To center the clutch plate, use the centering pin 3190 A.
- Install all bolts evenly, by hand, until the bolt heads contact the pressure 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.

Tightening specifications

- Install the transmission.