OVERVIEW - CLUTCH, "LuK"

Fig 1: Overview Of Clutch, "Luk" Assembly

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1. Clutch Module
   • Removing and installing. Refer to CLUTCH MODULE, REMOVING AND INSTALLING .
2. Shaft Seal
   • For the dual-mass flywheel
   • Removing. Refer to Figure
   • Installing. Refer to Figure
3. Needle Bearing
   • For the dual-mass flywheel
   • Different versions. Refer to Fig 3
   • Allocate correct components.
   • Checking and replacing if necessary. Refer to Fig 3
   • Removing. Refer to Figure
   • Installing. Refer to Figure
     NOTE:

     Always replace the needle bearing if the input shaft is damaged. Refer to DUAL MASS FLYWHEEL NEEDLE BEARING OR BALL BEARING, REPLACING => .

     Depending on the version, the needle bearing may have all rollers installed or it may be missing every 4th roller.

     Needle bearings missing the 4th roller must be replaced on 4-cylinder TDI vehicles (except 125 kW TDI). Refer to DUAL MASS FLYWHEEL NEEDLE BEARING OR BALL BEARING, REPLACING .

     On all other vehicles, the missing 4th roller is not a defect in the needle bearing. Do not replace the needle bearing!

4. Dual Mass Flywheel
   • With transfer plate
   • Make sure it fits securely on the centering pins
   • Keep the clutch lining contact surface free of grooves, oil and grease.
   • Different versions with and without centrifugal pendulum absorber. Refer to Fig 2.
   • Checking for damage. Refer to Fig 4
   • Removing and installing. Refer to CLUTCH, REMOVING AND INSTALLING, "LuK" .
5. Clutch Plate
   • Removing and installing. Refer to CLUTCH, REMOVING AND INSTALLING, "LuK" .
   • Allocate correct components.
   • Installed position: "Getriebeseite (transmission side)" faces the pressure plate
   • The spring pack (coil springs), if equipped, to the pressure plate
6. SAC Pressure Plate
   • Allocate correct components.
   • Removing and installing. Refer to CLUTCH, REMOVING AND INSTALLING, "LuK" .
   • Adjusting Ring, Resetting. Refer to CLUTCH PRESSURE PLATE ADJUSTING RING, RESETTING, "LuK" 
   • Check the ends of the diaphragm spring. Refer to Fig 7
   • Pressure Plate, Checking for Distortion. Refer to Fig 6
   • Check the pull-spring and rivet connections. Refer to Fig 8
   • Keep the clutch lining contact surface free of grooves, oil and grease.
7. Bolt
   • 22 Nm + 90° additional turn
   • Always replace.
   • For mount the pressure plate to the dual mass flywheel
   • Loosen or tighten according to assembly instructions. Refer to CLUTCH, REMOVING AND INSTALLING, "LuK" 

Fig 2: Turning Clutch Module -A- With Centrifugal Pendulum Absorber 90 Degrees (Clicking Noise Normal)

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A >>clicking<< is heard when turning the clutch module -A- approximately every 90°.

This noise comes from shifting pendulum masses (centrifugal pendulum absorber) in the dual mass flywheel and is not a fault.

Fig 3: Checking Needle Bearing Inside Dual Mass Flywheel On Vehicles With 4-Cylinder TDI Engine (Except On 125 kW TDI)

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Fig 4: Checking For Damages On The Dual Mass Flywheel

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-- Check the tabs -arrow A- and friction surface -arrow B- for cracks.

• Pay attention to the secure position of the centering pin -arrow C- in the dual mass flywheel.
• Dents or bumps must not be present on the surface -2- -arrow D-
• The transfer plate -3- must not be bent.

Housing wall damages on the dual mass flywheel

Fig 5: Dual Mass Flywheel Housing Wall Damage

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• A defective bow spring -1- or a defective bow spring bearing causes housing wall damage.

Fig 6: Checking SAC Pressure Plate For Warpage, Cracks And Burns

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A -

Ruler

B -

Feeler gauge

• Pressure plate deformation up to 0.8 mm is permitted.

Fig 7: Checking Ends Of Diaphragm Spring

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• Wear up to maximum 0.3 mm is permitted.

Fig 8: Checking Pull-Springs And Rivet Connection

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I -

Pull-springs OK

• Slight offset in the outer area -arrows A-.

II -

Pull-springs damaged

• The pressure plate must be replaced if the pull-spring is bent or broken off -arrow B-.

-- Make sure the rivet connections -arrows B- fit correctly on all pull-springs -arrows A-.

Fig 9: Checking Connections Of Springs And Rivet Connections

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• Replace any pressure plates that have loose rivet connections -arrow B-.