Clutch, Removing And Installing: Installing

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

NOTE:

Allocate clutch pressure plate and clutch plate according to the engine code.

Clean the input shaft splines and (on used clutch plates) the hub splines. Remove any corrosion and then apply a very thin coat of Lubricant on the splines. Then move the clutch plate back and forth on the input shaft until the hub moves freely on the shaft. Remove any excess grease.

The clutch pressure plates are corrosion-protected and greased. With the exception of the friction surface on the clutch plate, do not clean the clutch pressure plate. This will shorten the service life of the clutch considerably.

The friction surfaces on the clutch pressure plate and on the flywheel must be cleaned thoroughly (degreased).

To reduce odor caused by a burnt clutch, thoroughly clean the transmission housing around the clutch as well as the engine on the transmission side.

The clutch plate linings must sit completely on the flywheel and on the clutch pressure plate friction surface. Install the bolts.

Tighten the bolts diagonally in small steps so as to not damage the centering holes in the pressure plate and the centering pins on the flywheel.

Make sure the alignment sleeves for centering the engine/transmission are installed inside the cylinder block. Install them 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 plate installed location: The labeling "Getriebeseite" (transmission side) or the shorter end of the hub with the spring cage faces the pressure plate.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 1: Checking End Of Diaphragm Spring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

I - Pull-spring OK

Slight offset in the outer area -arrows A-.

II - Pull-springs damaged

The clutch pressure plates must be replaced if the pull-spring is bent or broken off -arrow B-.

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

Replace a clutch pressure plate with severely kinked or broken spring connections and loose rivet connections.

-- Make sure the rivet connections -arrows B- fit correctly on all pull-springs -arrows A-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten all bolts clockwise to the final tightening specification.

Replace any clutch pressure plates that have loose rivet connections -arrow B-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check the metal ring in the clutch pressure plate -arrow- for damage.

Replace any clutch pressure plates that have a broken metal ring.

-- Use the :3190A to center the clutch plate.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bolt diagonally in small steps.