Clutch, LuK

Clutch, LuK

Special tools, testers and auxiliary items required

• Flywheel Retainer (3067)

• Torque Wrench 5-50 Nm (V.A.G 1331)

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

• Centering Pin (T10097)

• Centering Mandrel (3176)

• On engines which have a crankshaft with a smaller diameter, or engines with a needle bearing in the crankshaft, refer to => [ Centering the clutch disc, removing
and installing the pressure plate on engines with a crankshaft with
a smaller diameter, or engines with a needle bearing in the crankshaft. ] Clutch, Sachs (3176).

Removing

• Remove the transmission.

- Use the (3067) to loosen the bolts.

- Loosen the bolt diagonally in small steps.

- Remove the pressure plate and the clutch plate.

Installing

Install in reverse order of removal. Pay attention to the following:

• Allocate the pressure plate and the clutch plate to match the engine code. Refer to the Parts Catalog.

• Check whether there are alignment sleeves for the engine/transmission in the cylinder block; install if necessary.

• If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).

Clutch Plate Installed Position





• "Getriebeseite" (transmission side) faces the transmission.

Check the Ends of the Diaphragm Spring





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

Checking the Spring Connections and Rivet Connections





- Check the spring connections - arrows A - for damage and make sure the rivet connections - arrows B - are tight.

Only check position of adjustment mechanism with new pressure plates





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

• 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.

• Replace clutch plates and pressure plates if the rivets are damaged or loose.

• Replace the pressure plate and the clutch plate together.

• Allocate the clutch plate and pressure plate to match the engine code. Refer to the Parts Catalog.

• Clean the input shaft splines and (on used clutch plates) the hub splines. Remove any corrosion and then apply a very thin coat of lubricant (G 000 100) on the splines. Then move the clutch plate back and forth on the input shaft until the hub moves freely on the shaft. Remove any excess grease.

• The pressure plates are corrosion-protected and lubricated. Only the running surfaces may be cleaned. Otherwise the service life of the clutch will be shortened considerably.

• The pressure plate contact surface and the clutch plate lining must completely touch the flywheel. Install the bolts.

- Install the (3067).






Engines having a crankshaft with a smaller diameter - arrow -, or engines having a needle bearing - arrow - in the crankshaft






Centering the clutch disc, removing and installing the pressure plate on engines with a crankshaft with a smaller diameter, or engines with a needle bearing - arrow - in the crankshaft.






• Ignore arrows - A and B -.

Continuation for All

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

- Press the pressure plate onto the alignment pin.

- Install all bolts evenly, by hand, until the bolt heads touch the pressure plate.

- Tighten the bolts in small steps and in diagonal sequence to prevent damaging the centering holes of the pressure plate and the centering pins of the dual mass flywheel - item 4 - => [ (Item 4) Bolt ] Clutch Overview, LuK.

• Install the transmission.