2003-2008 Volkswagen Golf 4 Door Clutch -> 3.2 ?Sachs? Clutch, Removing and Installing User Manual
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Clutch -> 3.2 ?Sachs? Clutch, Removing and Installing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– The outer contour of the flywheel can also be inspected by  
removing -arrows- the small cover plate -A-.  
Round Outer Contour -arrows- = Clutch Made by Sachs = -A-  
– Clutch, removing and installing, Sachs. Refer to  
⇒ “3.2 Sachs Clutch, Removing and Installing”, page 58 .  
– Sachs clutch, servicing. Refer to  
⇒ “3.3 Clutch, Servicing, Sachs ”, page 61 .  
Squared Outer Contour -arrows 1- and in Addition, A Pleat All the  
Way Around -arrow 2- = Clutch Made by LuK = -B-  
or  
Round Outer Contour -arrows 1- and A Circulated Depression  
-arrow 2- = Clutch Manufacturer, LuK = -B-  
– LuK clutch, removing and installing. Refer to  
⇒ “3.4 LuK Clutch, Removing and Installing”, page 62 .  
– LuK clutch, servicing. Refer to  
⇒ “3.5 Clutch, Servicing, LuK ”, page 65 .  
3.2  
“Sachs” Clutch, Removing and Installing  
Removing  
– Remove the transmission.  
– Insert Flywheel Retainer - 3067- to loosen the bolts.  
58  
Rep. Gr.30 - Clutch  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
– Loosen the bolt diagonally in small steps.  
When loosening, the stop -2- and the bolt -1- must loosen up  
•
together.  
– If the stop does not loosen: push the bolt toward the dual mass  
flywheel.  
– Remove the pressure plate and the clutch plate.  
Installing  
Install in reverse order of removal while. Note the following:  
Note  
♦ Allocate thrust plate and clutch disc according to the engine  
code. Refer to the Parts Catalog.  
♦ Check whether there are centering sleeves for the engine/  
transmission in the cylinder block; install 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 Position  
•
“Transmission side” label and the spring cage face the trans‐  
mission.  
Check the Ends of the Diaphragm Spring  
•
Wear up to half the thickness of the diaphragm spring  
-arrows- is permitted.  
3. Clutch, Servicing, Diesel  
59  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
Checking the Spring Connections and Rivet Connections  
– Check the spring connections between the pressure plate and  
the cover for cracks and make sure the rivet connections are  
tight.  
•
Replace the pressure plate if the spring connections are dam‐  
aged or if the rivet connections -arrows- are loose.  
Note  
♦ Replace clutch plates and pressure plates if the rivets are  
damaged or loose.  
♦ Allocate clutch disc and thrust plate using the engine code.  
Refer to the Parts Catalog.  
♦ Clean input shaft splines and (on used clutch plates) the hub  
splines, remove corrosion and apply a very thin coating of  
Grease for Clutch Disc Shaft Splines - G 000 100- to the  
splines. Then move the clutch plate back and forth on the input  
shaft until the hub moves freely on the shaft. Remove any ex‐  
cess grease.  
♦ The pressure plates are protected from corrosion and lubrica‐  
ted. Only the running surfaces may be cleaned. Otherwise the  
service life of the clutch will be shortened considerably.  
♦ The pressure plate contact surface and the clutch plate lining  
must completely touch the flywheel. Install the bolts.  
– Move the Flywheel Retainer - 3067- during installation.  
Engines Having A Crankshaft with A Smaller Diameter -arrow-,  
or Engines Having A Needle Bearing -arrow- in the Crankshaft  
60  
Rep. Gr.30 - Clutch  
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤  
6-Speed Manual Transmission 02Q - Edition 05.2013  
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.  
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):  
– Make sure the stop pin (position sensor) -arrow- moves easily.  
– Position the pressure plate on the centering pins.  
– Install all the bolts evenly, by hand, until the bolt heads contact  
the pressure plate.  
•
When doing this, the stop pin -arrow- must lift off from the  
pressure plate.  
– Tighten the bolts in small steps and in diagonal sequence to  
prevent damaging the centering holes of the pressure plate  
and the centering pins of the dual mass flywheel -item 4-  
⇒ Item 4 (page 62) .  
– Install the transmission.  
3.3  
Clutch, Servicing, “Sachs”  
3. Clutch, Servicing, Diesel  
61  

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