Removal And Installation: Clutch: SACHS

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.

Fig 1: Identifying Stop & Pin

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When loosening, the stop -2- and the bolt -1- must loosen up together.

-- If the stop does not loosen: push the bolt toward the dual mass flywheel.

-- 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 2: Installation Position Of Clutch Disc At Dual-Mass Flywheel

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"Getriebeseite" (transmission side) and the spring cage face the transmission.

Fig 3: Identifying Ends Of Diaphragm Spring

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

Fig 4: Identifying Spring Connections And Rivet Connections

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-- Check the spring connections between the pressure plate and the cover for cracks and make sure the rivet connections are tight.

Replace the pressure plate if the spring connections are damaged or if the rivet connections -arrows- are loose.

NOTE:

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

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

Clean the input shaft splines and (on used clutch discs) the hub splines, remove the 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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Fig 6: Identifying Crankshafts With Smaller Diameter or Needle Bearing

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Fig 7: Identifying Centering Clutch Plate And Pressure Plate

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NOTE:

Ignore arrows -A and B-.

Continuation for all Vehicles:

When installing, tighten the bolts as follows so the pressure plate does not distort (causing shuddering on acceleration):

Fig 8: Identifying Pressure Plate Stop Pin (Position Sensor)

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-- Make sure the stop pin (position sensor) -arrow- moves easily.

-- Position the pressure plate on the alignment pins.

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

When doing this, the stop pin -arrow- must lift off from 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.