Removal And Installation: Clutch: LUK

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Removing

-- Remove the transmission.

-- Install the flywheel retainer 3067 to loosen the bolts.

-- Loosen the bolt diagonally and in small steps.

-- Remove the pressure plate and the clutch disc.

Installing

Installation is performed in the reverse order of removal while observing the following:

NOTE:

Allocate the pressure plate and the clutch disc to match the engine code.

Check whether there are alignment sleeves for the engine/transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).

Fig 1: Installation Position Of Clutch Disc At Dual-Mass Flywheel

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"Getriebeseite" (transmission side) faces the transmission.

Fig 2: Identifying Ends Of Diaphragm Spring

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Wear up to half the thickness of the diaphragm spring -arrows- is permitted.

Fig 3: Identifying Connections Of Springs And Rivet Connections

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-- Check the spring connections -arrows A- for damage and make sure the rivet connections -arrows B- are tight.

Fig 4: Identifying Edges Of Adjusting Ring Position

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Both edges -A- of the adjusting ring must be located between both notches -arrows B-.
If the adjusting ring takes on a different position with a new pressure plate, the pressure plate and clutch disc must not be installed.
With used clutches, the adjusting ring may take on a position outside of the notches.

NOTE:

Replace the clutch disc and pressure plate if the rivets are damaged or loose.

Replace the pressure plate and the clutch disc together.

Allocate the clutch disc and pressure plate to match the engine code. .

Clean input shaft splines and (on used clutch discs) the hub splines, remove corrosion and apply a very thin coating of grease for clutch plate splines G 000 100 to the splines. Then move the clutch disc back and forth on the input shaft until the hub moves freely on the shaft. Remove any excess grease.

The pressure plate is corrosion-protected and lubricated. Only the running surfaces may be cleaned. Otherwise the service life of the clutch will be shortened considerably.

The pressure plate contact surface and the clutch disc lining must completely touch the flywheel. Install the bolts.

-- Remove the flywheel retainer 3067 when installing.

Fig 5: Identifying Flywheel Retainer 3067 Repositioned For Installation

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Crankshafts with a Smaller Diameter -arrow-, or a Needle Bearing -arrow-

Fig 6: Identifying Crankshafts With Smaller Diameter or Needle Bearing

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Centering the Clutch Disc, Removing/Installing the Pressure Plate with a Crankshaft with a Smaller Diameter, or a Needle Bearing.

Fig 7: Identifying Centering Clutch Plate And Pressure Plate

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NOTE:

Ignore arrows -A and B-.

Continuation for all Vehicles:

-- Position the pressure plate on the alignment pins.

-- Install all the bolts evenly, by hand, until the bolt heads contact the pressure plate.

-- Tighten the bolts in small steps and in a diagonal sequence to prevent damaging the centering holes of the pressure plate and the centering pins of the dual mass flywheel 4.

-- Install the transmission.