Clutch Module, Removing And Installing
Special tools and workshop equipment required
- Puller - Clutch Module T40176
- Puller - Flanged Shaft T10037
- Slide Hammer Set - Hammer VW771/1
- Grease for Clutch Disc Shaft SplinesG 000 100
- Sealing Grease G 052 128 A1
Remove the Clutch Module
-- Remove the transmission and secure it to the Gearbox Support T40173 using a tensioning strap -1-. Refer to TRANSMISSION, REMOVING AND INSTALLING .
- Tilt the transmission back slightly to prevent transmission fluid from leaking when removing the left flange shaft.
-- Remove bolts -arrows- on left flange shaft mounting bracket.
-- Remove the flange shaft from the transmission in the direction of arrow -A-. Keep the end of the shaft -2- centered on the front final drive opening -arrow 3-.
Danger of damaging the shaft seal.
- If the shaft is not centered when removing, the shaft splines -2- fall onto the inner shaft seal -arrow 3- between the final drive and the transmission housing.
- Always replace a damaged shaft seal. Refer to LEFT SEAL, REPLACING .
If it is not possible to remove the left flange shaft by hand, then use the Slide Hammer SetVW771 to remove it.
-- Attach the plate from the Puller - Flanged Shaft T10037 to the flange shaft -arrows- and attach the spindle from the Slide Hammer SetVW771 (nuts -A-).
-- Attach the Puller - Clutch Module T40176 to the clutch module -A- with the nut -B- -arrow-.
-- Turn the Puller - Clutch Module T40176 upward.
Danger of damaging the shaft seals and the needle bearings in the dual mass flywheel.
- The clutch module weighs approximately 20 kg (44 lbs.).
- To prevent the clutch module from tipping, counterhold it at the bottom as shown in the illustration.
- When removing and installing the clutch module, make sure the shaft seals and the needle bearing in the dual mass flywheel -arrow- are not damaged.
- Replace the damaged shaft seals or needle bearings. Refer to DUAL MASS FLYWHEEL NEEDLE BEARING, REMOVING AND INSTALLING .
-- Remove the clutch module without tilting the input shaft -arrow-.
Danger of causing damage to the transfer plate on the dual mass flywheel.
- Do not lay the clutch module on one side on the transfer plate -arrow-.
- This could bend the transfer plate -arrow-, which will then lead to functionality problems.
-- Lay the clutch module on a work bench with the clutch pressure plate facing down.
Install the Clutch Module.
Install in reverse order of removal. Note the following:
-- Lubricate the release bearing according to the specification. Refer to Figure.
-- Always clean the left flange shaft, the transmission housing in the area where the differential is accessed -arrow A- and the shaft seal -arrow B-.
Replace the shaft seal between the differential and transmission housing -arrow B- if it is damaged. Refer to LEFT SEAL, REPLACING .
-- Fill the space between the sealing and dust lip -arrow B- halfway with Sealing Grease G 052 128 A1.
-- Clean the input shaft -arrow-.
-- Lubricate the input shaft splines using Grease for Clutch Disc Shaft SplinesG 000 100.
Remove any grease on the pivot pin on the input shaft -arrow- all the way up to the splines before installation.
-- Slide the clutch module onto the input shaft carefully without tilting it.
-- Remove the Puller - Clutch Module T40176 from the clutch module.
-- Rotate the clutch module -1- until the opening to the differential -arrow 3- is seen.
-- Insert the left flange shaft into the transmission in the direction of -arrow B- and guide the end of the shaft -2- into the shaft seal on the front differential -arrow 3-, keeping the shaft centered.
Danger of damaging the shaft seal.
- If the shaft is not centered, the shaft splines -2- will damage the shaft seal -arrow 3- between the differential and transmission housing.
- Always replace a damaged shaft seal. Refer to LEFT SEAL, REPLACING .
-- Tighten the left flange shaft mounting bracket -arrows-. Tightening specification: 24 Nm