Clutch, Servicing

Clutch, servicing, 012/01W, 5 SPD. M/T

Special tools, testers and auxiliary items required:

^ Flywheel Retainer 3067
^ Centering Mandrel 3176
^ Torque Wrench 5-50 Nm V.A.G. 1331

(transmission removed)

Note:
^ Replace clutch discs and pressure plates with damaged or loose rivets.
^ Allocate clutch disc and pressure plate according to Electronic Parts Catalog (ETKA) and engine code.
^ Clutch is depicted in conjunction with dual-mass flywheel.





1. Flywheel
^ Make sure centering pins are in place and seated correctly
^ Contact surface for clutch lining free of dirt, oil and grease
^ If present, place white dots on flywheel - A - and pressure plate - B - pointing toward each other.

2. Clutch disc
^ Allocate via Electronic Parts Catalog (ETKA)
^ Installed position for dual-mass flywheel: clutch plate lining must contact flywheel
^ Installed position at simple flywheel: spring cage faces pressure plate
^ Marking "Getriebeseite", if available, always points toward pressure plate or transmission
^ Centering
^ Lightly lubricate splines

Note:
^ Clean input shaft splines and (in case of used clutch plates) clean hub splines. Remove corrosion and apply only a very thin coating of lubricant G 000 100 on input shaft splines. Then move clutch disc on input shaft back and forth until hub on shaft moves easily. Always remove excessively applied grease.

3. Pressure plate
^ Removing and installing
^ Checking ends of the diaphragm spring
^ Check spring connection and rivets
^ Check wire ring
^ If present, place white dots on flywheel - A - and pressure plate - B - pointing toward each other.

Note:
^ Pressure plates are protected against corrosion and greased. Only the contact surface may be cleaned, otherwise service life of clutch is significantly reduced.

4. Bolt, 25 Nm
^ Loosen and tighten in stages and in diagonal sequence

5. Needle bearing
^ Driving out and in





Centering clutch plate and removing and installing pressure plate
^ Loosen and tighten bolts in stages and in diagonal sequence.
^ Move retainer when removing.
^ When installing, make sure that, if present, white dots on dual-mass flywheel - A - and pressure plate - B - point toward each other.

Note:
^ Contact surface of thrust plate and clutch disc lining must make complete contact on flywheel. Tighten securing bolts uniformly in diagonal sequence so that thrust plate centering holes and flywheel centering pins are not damaged.





Checking ends of the diaphragm spring
^ Wear up to half the thickness of the diaphragm spring is permitted.

Note:
^ Allocate clutch thrust plate and clutch disc via engine code according to Electronic Parts Catalog (ETKA)





Check spring connection and rivets
^ Check spring connections - arrows A - for damage and rivets - arrows B - for secure seating.

Note:
^ Thrust plates with very kinked or broken spring connections as well as loose rivets must be replaced.





Check wire ring
^ Check wire ring in thrust plate - arrow - for damage. Replace thrust plate when wire ring is broken.