Clutch, Removing And Installing, With Dual Mass Flywheel, LUK: Installing

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

Install in the reverse order of removal while noting the following:

NOTE:

Allocate clutch pressure plate and clutch plate according to the engine code. Refer to the Parts Information.

Clean the input shaft splines and (on used clutch plates) the hub splines. Remove any corrosion and only apply a very thin coating of Lubricating Grease for Clutch Plate Splines 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 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 Installation Position

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

"Transmission side" label faces the transmission.

Check the Ends of the Diaphragm Spring

Fig 2: Checking Ends Of Diaphragm Spring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Tension Springs and Rivet Connection, Checking

Fig 3: Checking Pull-Springs And Rivet Connection

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

I - Tension spring OK

Slight offset in the outer area -arrows A-.

II - Tension spring damaged

Clutch pressure plates must be replaced if the tension springs are bent or broken off -arrow B-.

Checking the Spring Connections and Rivet Connections

Fig 4: Check Connections Of Springs And Rivet Connections

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Make sure the rivet connections -arrows B- have a secure fit at all tension springs -arrows A-.

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

Only Check the Position of the Adjustment Mechanism with New Pressure Plates

Fig 5: Identifying Edges Of Adjusting Ring Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 new pressure plates, pressure plate and clutch plate must not be installed.
With used clutches, the adjusting ring may take on a position outside of the notches.

-- Use the :3067 when installing.

Fig 6: Identifying Flywheel Retainer 3067 Repositioned For Installation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Centering the Clutch Plate, 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Ignore arrows -A and B-.

Continuation for All

When Installing, Tighten Bolts as Follows so 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 clutch pressure plate.

-- Tighten the bolt diagonally in small steps.

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