Get Clutch -> 3 Clutch, Servicing, Diesel Guide for 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

3

Clutch, Servicing, Diesel

⇒ “3.1 Determining Clutch Manufacturer”, page 57

⇒ “3.2 Sachs Clutch, Removing and Installing”, page 58

⇒ “3.3 Clutch, Servicing, Sachs ”, page 61

⇒ “3.4 LuK Clutch, Removing and Installing”, page 62

⇒ “3.5 Clutch, Servicing, LuK ”, page 65

Special tools and workshop equipment required

♦ Flywheel Retainer - 3067-

♦ Alignment Tool - Clutch Plate - T10097-

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Grease for Clutch Disc Shaft Splines - G 000 100-

♦ On engines which have a crankshaft with a smaller diameter,

or engines with a needle bearing in the crankshaft. Refer to

⇒ Fig. ““Centering the Clutch Disc, Removing and Installing

the Pressure Plate on Engines with A Crankshaft with A Small‐

er Diameter, or Engines with A Needle Bearing in the Crank‐

shaft.”“ , page 61 Alignment Tool - Clutch Plate - 3176- .

3.1

Determining Clutch Manufacturer

Either a “Sachs” or a “LuK” clutch may be installed.

It is possible to tell which clutch the vehicle has with the trans‐

mission installed:

– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 50 ; Noise Insulation .

– Remove the noise insulation from the oil pan if necessary.

There are some openings -arrows- between the engine -A- and

the transmission -B- near the bottom of the oil pan.

– Check the outer contour of the flywheel through this opening.

3. Clutch, Servicing, Diesel

57

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

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

1 - Dual Mass Flywheel

❑ Removing and instal‐

ling. Refer to ⇒ Rep.

Gr. 13 .

❑ Make sure it fits secure‐

ly on the centering pins

❑ Keep the clutch lining

contact surface free of

grooves, oil and grease.

2 - Clutch Plate

❑ Allocation. Refer to the

Parts Catalog.

❑ Only replace together

with the pressure plate

❑ Removing and instal‐

ling. Refer to

⇒ “3.2 Sachs Clutch,

Removing and Instal‐

ling”, page 58 .

❑ Installation position. Re‐

fer to

⇒ Fig. ““Clutch Plate In‐

stalled Position”“ ,

page 59 .

3 - Pressure Plate

❑ With adjustment mech‐

anism

❑ Allocation. Refer to the

Parts Catalog.

❑ Only replace together

with the clutch plate

❑ Removing and instal‐

ling. Refer to

⇒ “3.2 Sachs Clutch,

Removing and Instal‐

ling”, page 58 .

❑ Checking the ends of the diaphragm spring. Refer to

⇒ Fig. ““Check the Ends of the Diaphragm Spring”“ , page 59

❑ Checking the spring connections and rivet connections. Refer to

⇒ Fig. ““Checking the Spring Connections and Rivet Connections”“ , page 60

4 - Bolt

❑ M6 bolt: 13 Nm

❑ M7 bolt: 20 Nm

❑ Allocation. Refer to the Parts Catalog.

❑ Loosen or tighten in small steps and in diagonal sequence

3.4

“LuK” Clutch, Removing and Installing

Removing

– Remove the transmission.

– Insert Flywheel Retainer - 3067- to loosen the bolts.

– Loosen the bolt diagonally in small steps.

– Remove the pressure plate and the clutch plate.

62

Rep. Gr.30 - Clutch

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

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 faces the transmission.

Check the Ends of the Diaphragm Spring

•

Wear up to half the thickness of the diaphragm spring

-arrows- is permitted.

Checking the Spring Connections and Rivet Connections

– Check the spring connections -arrows A- for damage and

make sure the rivet connections -arrows B- are tight.

3. Clutch, Servicing, Diesel

63

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Only Check Position of Adjustment Mechanism with New Pres‐

sure Plates

•

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 pres‐

sure plates, pressure plate and clutch plate must not be in‐

stalled.

•

With used clutches, the adjusting ring may take on a position

outside of the notches.

Note

♦ Replace clutch plates and pressure plates if the rivets are

damaged or loose.

♦ Replace the pressure plate and the clutch plate together.

♦ 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

64

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

– Position the pressure plate on the centering pins.

– Install all the bolts evenly, by hand, until the bolt heads contact

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 66) .

– Install the transmission.

3.5

Clutch, Servicing, “LuK”

1 - Dual Mass Flywheel

❑ Removing and instal‐

ling. Refer to ⇒ Rep.

Gr. 13 .

❑ Make sure it fits secure‐

ly on the centering pins

❑ Keep the clutch lining

contact surface free of

grooves, oil and grease.

2 - Clutch Plate

❑ Allocation. Refer to the

Parts Catalog.

❑ Removing and instal‐

ling. Refer to

⇒ “3.4 LuK Clutch, Re‐

moving and Installing”,

page 62 .

❑ Only replace together

with the SAC pressure

plate

❑ Installation position. Re‐

fer to

⇒ Fig. ““Clutch Plate In‐

stalled Position”“ ,

page 63

3 - SAC Pressure Plate

❑ SAC = “Self Adjusting

Clutch”

❑ Only replace together

with the clutch plate

❑ Allocation. Refer to the

Parts Catalog.

❑ Removing and instal‐

ling. Refer to

⇒ “3.4 LuK Clutch, Re‐

moving and Installing”,

page 62 .

3. Clutch, Servicing, Diesel

65

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ Checking the ends of the diaphragm spring. Refer to

⇒ Fig. ““Check the Ends of the Diaphragm Spring”“ , page 63

❑ Checking the spring connections and rivet connections. Refer to

⇒ Fig. ““Checking the Spring Connections and Rivet Connections”“ , page 63

4 - Bolt

❑ M6 bolt: 13 Nm

❑ M7 bolt: 20 Nm

❑ Loosen or tighten in small steps and in diagonal sequence

66

Rep. Gr.30 - Clutch

Clutch -> 3 Clutch, Servicing, Diesel for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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