Clutch, SACHS

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Flywheel Retainer 3067
Centering Mandrel 3190 A
Torque Wrench (5-50 Nm) V.A.G 1331
Grease for Clutch Plate Splines G 000 100

Requirement:

The transmission is removed.

Removing

-- 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: Press the pin in the direction of 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:

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) faces the transmission.

Fig 3: Checking Ends Of Diaphragm Spring

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

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.

-- Remove the flywheel retainer 3067 when installing.

Fig 5: Centering Clutch Plate And Removing And Installing Pressure Plate

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

Fig 6: Checking Stop Pin (Position Sensor)

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

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

-- Position the pressure plate on the alignment sleeves.

-- Use the centering mandrel 3190 A to center the clutch plate.

-- 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 alignment sleeves of the dual mass flywheel.

Tightening specification, see -item 4- in CLUTCH OVERVIEW, SACHS .

Install the transmission.