Get Clutch -> 4 Clutch, Servicing, Gasoline 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

4

Clutch, Servicing, Gasoline

⇒ “4.1 Clutch, Servicing”, page 67

⇒ “4.2 Clutch, Removing and Installing”, page 68

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

⇒ page 71 Alignment Tool - Clutch Plate - 3176- .

4.1

Clutch, Servicing

Note

♦ Make sure the alignment bushings 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 trans‐

mission may make noises (loose rattling).

4. Clutch, Servicing, Gasoline

67

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.

❑ Removing and instal‐

ling. Refer to

⇒ “4.2 Clutch, Remov‐

ing and Installing”, page

68 .

❑ Only replace together

with the SAC pressure

plate

❑ Installation position. Re‐

fer to

⇒ Fig. ““Clutch Plate In‐

stalled Position”“ ,

page 69

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

⇒ “4.2 Clutch, Remov‐

ing and Installing”, page

68 .

❑ Checking the ends of the diaphragm spring. Refer to

⇒ Fig. ““Check the Ends of the Diaphragm Spring”“ , page 69

❑ Checking the spring connection and rivet connections. Refer to

⇒ Fig. ““Checking the Spring Connections and Rivet Connections”“ , page 69

4 - Bolt

❑ M6: 13 Nm

❑ M7: 20 Nm

❑ Loosen or tighten in small steps and in a diagonal sequence.

4.2

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.

Installing

Install in reverse order of removal while. Note the following:

68

Rep. Gr.30 - Clutch

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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

•

“Getriebeseite” (transmission side) -arrow- faces the trans‐

mission.

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.

4. Clutch, Servicing, Gasoline

69

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 the clutch plate and pressure plate to match the en‐

gine code. Refer to the Parts Catalog.

♦ To reduce odor caused by a burnt clutch, thoroughly clean the

clutch housing, the flywheel and the side of the engine facing

toward the transmission.

♦ 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.

70

Rep. Gr.30 - Clutch

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Engines having A Crankshaft with A Smaller Diameter -arrow-, or

Engines having A Needle Bearing -arrow- in the Crankshaft

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 68) .

– Install the transmission.

4. Clutch, Servicing, Gasoline

71

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

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