OVERVIEW - CLUTCH, "Sachs"

• Clutch information. Refer to CLUTCH, GENERAL INFORMATION .
• How to recognize. Refer to Fig 2

Fig 1: Overview Of Clutch, "Sachs" 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 or Ball Bearing
   • For the dual-mass flywheel
   • Different versions. Refer to Fig 5
   • Allocate correct components.
   • Checking and replacing if necessary. Refer to Fig 5
   • Removing. Refer to Figure
   • Installing. Refer to Figure
     NOTE:

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

     Depending on the version, the ball bearing or 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.
   • Removing and installing. Refer to CLUTCH, REMOVING AND INSTALLING, "Sachs" .
   • Check the plastic washer inside the dual mass flywheel. Refer to Fig 3
   • Measure the wear on the plastic washer. Refer to Fig 4
   • Checking for damage. Refer to Fig 6
5. Clutch Plate
   • Removing and installing. Refer to CLUTCH, REMOVING AND INSTALLING, "Sachs" .
   • Allocate correct components.
   • Installed position: "Getriebeseite (transmission side)" faces the pressure plate
   • The spring pack (coil springs), if equipped, to the pressure plate
6. Pressure Plate
   • Self-adjusting
   • How to recognize. Refer to Fig 2
   • The pressure plate and clutch plate can only be replaced together.
   • Allocate correct components.
   • Removing and installing. Refer to CLUTCH, REMOVING AND INSTALLING, "Sachs" .
   • Pressure Plate, Checking for Distortion. Refer to Fig 8
   • Check the ends of the diaphragm spring. Refer to Fig 9
   • Check the pull-springs and rivet connections. Refer to Fig 10
   • Check the metal ring. Refer to Fig 12
   • Keep the clutch lining contact surface free of grooves, oil and grease.
7. Bolt (See Fig 1)
   • 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, "Sachs" 

Fig 2: Checking Pressure Plate Does Not Distort

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Pressure plate with a position sensor -arrow- or "Sachs" written on it.

Fig 3: Checking Dual Mass Flywheel

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• The "white" plastic washer -A- must be inside the dual mass flywheel. If must be under the copper-colored sliding washer -B- and above the shaft seal -C-.
• If the "white" plastic washer -A- is missing, then the dual mass flywheel must be replaced.
• Measure the wear on the plastic washer -A-. Refer to Fig 4

Fig 4: Checking Dual Mass Flywheel Plastic Washer

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-- Clean the copper-colored sliding washer -A- and the shaft seal -B- at the measuring locations.

-- Push the sliding washer -A- toward the shaft seal -B-.

-- Measure the distance -x- from the top of the copper-colored sliding washer -A- to the top of the shaft seal -B- on the outer edge using the Depth Gauge.

• Dimension -x- minimum 2.5 mm
• If the dimension -x- is less than 2.5 mm, then the dual mass flywheel must be replaced.

Fig 5: Checking Needle Bearing Inside Dual Mass Flywheel On Vehicles With 4-Cylinder TDI Engine (Except On 125 kW TDI)

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Fig 6: 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 7: 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 8: 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 9: Checking Ends Of Diaphragm Spring

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• Wear up to maximum 0.3 mm is permitted.

Fig 10: 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 -A-.

Fig 11: Checking Connections Of Springs And Rivet Connections

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

Fig 12: Identifying Wire Ring In Thrust Plate

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-- Check the metal ring inside the pressure plate for damage -arrow-.

• Replace any pressure plates that have a broken metal ring.