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

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"Transmission side" label and the spring cage face the transmission.

Check the Ends of the Diaphragm Spring

Fig 2: Checking End Of Diaphragm Spring

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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

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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 Spring Connection And Rivet Connection

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

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

-- Use the :3067 when installing.

Fig 5: 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 6: Crankshafts With Smaller Diameter Or Needle Bearing

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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 7: 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):

Fig 8: Checking Pressure Plate Does Not Distort

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

-- Install the pressure plate on the centering pins.

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

-- Tighten the bolt diagonally in small steps.

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

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