Clutch Module, Removing And Installing

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Special tools and workshop equipment required

Puller - Clutch Module T40176
Grease for Clutch Disc Shaft Splines G 000 100

Removing

Fig 1: Identifying Transmission Holding Fixture

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-- Remove the transmission and secure it to the Gearbox Support T40173 using a tensioning strap -1-. .

Transmission removed. Refer to TRANSMISSION, REMOVING AND INSTALLING .
The transmission is secured on the Gearbox Support T40173 with the tensioning strap -1- (See Fig 1).

-- Tilt the transmission toward the rear using the Gearbox Support T40173 so that no transmission fluid drains out.

-- Remove the left flange shaft. Refer to RIGHT SEAL, REPLACING .

Fig 2: Identifying Bolts & Flange Shaft Mounting Bracket

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-- Attach the Puller - Clutch Module T40176 to the clutch module -A- with the nut -B- -arrow-.

Fig 3: Securing T40176 To Torque Converter

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-- Turn the Puller - Clutch Module T40176 upward.

Fig 4: Removing/Installing Flywheel Components

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CAUTION:

Danger of damaging the shaft seals and the needle bearings in the dual mass flywheel.

The clutch module weighs approximately 20 kg.
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 OR BALL BEARING, REPLACING .

-- Remove the clutch module without tilting the input shaft -arrow-.

Fig 5: Identifying Transfer Plate

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CAUTION:

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.

4-cylinder TDI vehicles (except 125 kW TDI)

Fig 6: Checking Needle Bearing Inside Dual Mass Flywheel On Vehicles With 4-Cylinder TDI Engine (Except On 125 kW TDI)

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CAUTION:

See which needle bearing is installed inside the dual mass flywheel.

Depending on the version, the ball bearing or needle bearing may have all rollers installed or it may be missing every 4th roller.
If needle bearing -B- is missing every 4th roller -arrows-, it 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!
Depending on the manufacturer the needle bearing is either completely equipped with rollers -A - or with balls -C-.

Depending on the manufacture vehicles with 4-cylinder TDI engines (except 125 kW-TDI) the following bearing is installed:

>>LuK<< dual mass flywheel: needle bearing -A-, completely equipped with rollers.
>>Sachs<< dual mass flywheel: ball bearing -C-.
Allocate correct components.

Install The Clutch Module .

Fig 7: Carefully Set Down Electro-Drive Drive Motor

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Install in reverse order of removal. Note the following:

-- 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-.

NOTE:

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.

-- Lubricate the release bearing according to the specification. Refer to Figure.

Fig 8: Checking Input Shaft For Scoring

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-- Clean the input shaft splines and pivot pin -arrow-.

-- Lubricate the input shaft splines using Grease for Clutch Disc Shaft Splines G 000 100.

CAUTION:

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 -arrow- carefully without tilting it.

Fig 9: Removing/Installing Flywheel Components

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-- Remove the Puller - Clutch Module T40176 from the clutch module.

-- Install the left flange shaft. Refer to LEFT FLANGE SHAFT, REMOVING AND INSTALLING => .