Clutch, With Dual Mass Flywheel, LUK: Installing

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Install in reverse order of removal. Note the following:

NOTE:

Allocate the pressure plate and the clutch disc to match 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 G 000 100 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.

Only use compressed air to clean the dual mass flywheel.

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 pins for centering the engine/transmission are installed inside the cylinder block. Install them if necessary.

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

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

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"Getriebeseite" (transmission side) faces the transmission.

Fig 2: Checking Ends Of Diaphragm Spring

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

Fig 3: Checking Pull-Springs And Rivet Connection

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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-.

Fig 4: Check Connections Of Springs And Rivet Connections

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

Replace a clutch pressure plate that has loose rivet connections -arrows B-.

Fig 5: 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.

-- Install the flywheel retainer 3067.

Fig 6: Identifying Flywheel Retainer 3067 Repositioned For Installation

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Engines having a crankshaft with a smaller diameter -arrow-, or engines having a needle bearing -arrow- in the crankshaft:

Fig 7: Crankshafts With Smaller Diameter Or Needle Bearing

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Centering the clutch disc, removing and installing the pressure plate on engines with a crankshaft with a smaller diameter, or engines with a needle bearing in the crankshaft:

Fig 8: Centering Clutch Plate And Removing And Installing Pressure Plate

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NOTE:

Ignore arrows -A and B-.

Continuation for All:

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

-- Install the pressure plate on the centering pins.

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

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

-- Install the transmission, refer to TRANSMISSION, INSTALLING .