Self-adjusting clutch (Sachs version), removing and installing

WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Flywheel Retainer 3067

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Flywheel retainer 3067

Fig 2: Identifying Centering Mandrel 3176

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Centering mandrel 3176
Grease for clutch plate splines G000100

Fig 3: Changing Over Flywheel Retainer 3067

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Attach flywheel retainer 3067 or counter-hold tool 10 - 201 before loosening bolts.

Fig 4: Identifying Stop & Pin

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To prevent the pressure plate from becoming distorted during removal (causes clutch grab when driving off), always adhere to the following procedure when unbolting the pressure plate:

Loosen all six bolts consecutively in clockwise direction and in steps of 90° (14 turn) until pressure plate is released.

Stop - 2 - (position sensor) with pin - 1 - should come free when bolts are loosened.

Installing

Installation position of clutch plate: coil springs (damper assembly) or marking "Getriebeseite" point toward pressure plate and transmission.

Fig 5: Changing Over Flywheel Retainer 3067

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To remove, reverse position of flywheel retainer 3067 or counter-hold tool 10 - 201.
Use centering mandrel 3176 to centralize clutch plate.

Fig 6: Pressure Plate With Impact (Position Sensor)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To prevent the pressure plate from becoming distorted during installation (causes clutch grab when driving off), always adhere to the following procedure when installing pressure plate:

Position pressure plate on dowel pins.
Make sure that the stop mechanism (position sensor) - arrow - is free to move.
Screw in all 6 bolts evenly by hand until bolt heads make contact with pressure plate.
Tighten all six bolts consecutively in clockwise direction and in steps of 90° (14 turn) until the housing makes contact with flywheel.

The stop pin - arrow - should then lift away from pressure plate.
Tighten all 6 bolts to final torque (22Nm) consecutively in clockwise direction.