OVERVIEW - CLUTCH, "Single-Disc Clutch - LuK"

Fig 1: Clutch, LUK Assembly Overview

Courtesy of AUDI OF AMERICA, LLC

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 2
   • Checking and replacing if necessary. Refer to Fig 2
   • 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, REMOVING AND INSTALLING => If the surface of the input shaft is visibly damaged near the needle bearing in the dual mass flywheel -arrow-, then replace both the input shaft and the needle bearing in the dual mass flywheel. .

     Depending on the version, the needle bearing may have all rollers installed or it may be missing every 4th roller. This does not mean that the needle bearing is defective.

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, "Single-Disc Clutch - LuK" .
5. Clutch Plate
   • Removing and installing. Refer to CLUTCH, REMOVING AND INSTALLING, "Single-Disc Clutch - 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, "Single-Disc Clutch - LuK" .
   • Adjusting Ring, Resetting. Refer to CLUTCH PRESSURE PLATE ADJUSTING RING, RESETTING 
   • Check the ends of the diaphragm spring. Refer to Fig 4
   • Pressure Plate, Checking for Distortion. Refer to Fig 3
   • Check the pull-spring and rivet connections. Refer to Fig 5
   • 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, "Single-Disc Clutch - LuK" 

Fig 2: Check the Needle Bearing Inside the Dual Mass Flywheel

Courtesy of AUDI OF AMERICA, LLC

Depending on the Version, the Following Bearings Are Installed in the Dual Mass Flywheel:

• Needle bearing -A- that has a complete set of rollers
• Needle bearing -B-, that is missing every 4th roller -arrows- does not indicate a faulty needle bearing.
• New needle bearings are equipped with rollers.
• Ball bearing -C-.

Fig 3: Check SAC Pressure Plate For Warpage, Cracks And Burns

Courtesy of AUDI OF AMERICA, LLC

A -

Ruler

B -

Feeler gauge

• Pressure plate deformation up to 0.8 mm is permitted.

Fig 4: Checking Ends Of Diaphragm Spring

Courtesy of AUDI OF AMERICA, LLC

• Wear up to maximum 0.3 mm is permitted.

Fig 5: Checking Pull-Springs And Rivet Connection

Courtesy of AUDI OF AMERICA, LLC

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 6: Check Connections Of Springs And Rivet Connections

Courtesy of AUDI OF AMERICA, LLC

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