Clutch, SACHS

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Flywheel Retainer 3067
Torque Wrench (5-50 Nm) V.A.G 1331
Centering Pin T10097
Centering Mandrel 3176 (For engines which have a crankshaft with a smaller diameter)
Grease for Clutch Plate Splines G 000 100

Removing

Remove the transmission.

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

-- Loosen the bolts 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).

Clutch Disc Installed Position

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.

Check the Ends of the Diaphragm Spring

Fig 3: Checking Ends Of Diaphragm Spring

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

Check the Spring and Rivet Connections

Fig 4: Check 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 any corrosion and then apply a very thin coat of grease for clutch plate splines G 000 100 on 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: Repositioning Flywheel Retainer 3067 For Installation

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Engines having a crankshaft with a smaller diameter -arrow-.

Fig 6: Crankshafts with a Smaller Diameter or Needle Bearing

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Fig 7: Centering Clutch Plate And Removing And Installing 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: 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, see Figure.

Install the transmission.