Dismantling and assembling clutch "F": VW Passat B5 / Phaeton

🧭 Before you start

Fits: VW Passat B5 (3B), VW Phaeton (3D)

Don't miss

• Ensure that the rounded edges of the last outer plate face towards friction plate (4), not towards retaining ring (5). This improves the contact surface for the retaining ring.
• Mark contact point on cylinder "“F”".
• Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points.
• (Item 2) can be disregarded.

📋 Procedure

1. Turn clutch (F) upside down.
2. Remove retaining ring (1) and remove set of plates (2) from cylinder "“F”".
3. Press down dished spring using workshop press with assembly jig T10289.
4. Remove split retaining ring (1).
5. Release workshop press.

6. Remove pressure plate and dished spring.
7. Set cylinder "“F”" on clutch "“D/G”" with freewheel.
8. ⚠ Wear eye protection. — Carefully press piston "“F”" out of cylinder "“F”" by applying compressed air as shown in figure.
9. ⚠ Before assembly, check the individual components of clutch "“F”" for traces of wear and damage . — Renew O-rings (2) and (4) for piston "“F”", (item 3).
10. Push piston "“F”", (item 3) into cylinder "“F”", (item 1) to stop.
11. Fit pressure plate (5).
12. Fit dished spring (6).
13. Press down dished spring using workshop press with assembly jig T10289.
14. Insert split retaining ring (1).
15. Release workshop press.
16. Fit corrugated spring (2) into cylinder "“F”", (item 1).
17. Fit outer plates (3) and friction plates (4) alternately. [Note: Ensure that the rounded edges of the last outer plate face towards friction plate (4), not towards retaining ring (5). This improves the contact surface for the retaining ring.]
18. Insert retaining ring (5).
19. Set clutch "“F”" on compressor tool T10285.
20. Position holding plate T10292 on outer plate of clutch "“F”".
21. Fit centring pin of thrust piece T10285/1 into drilling in plate.
22. Bring clutch "“F”" into correct position on holding plate of compressor tool.
23. Turn spindle of compressor tool downwards.
24. Position digital depth gaugeVAS 6087 on upper edge of cylinder "“F”" as shown in figure.
25. Bring measuring tip into contact with outer plate and note value obtained.
26. Mark contact point on cylinder "“F”".
27. Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points.
28. Determine average value from the three measurements under load.
29. Release spindle and remove holding plate.
30. Use both hands to pull set of plates upwards to stop in clutch "“F”".
31. With set of plates pulled up to stop, measure distance between upper edge of cylinder "“F”" and outer plate at one of the marked points (assistance of second mechanic required).
32. Repeat measurement at the two remaining markings on the outer plate.
33. Determine average value from the three measurements with set of plates pulled to stop.
34. Determine clearance using the following formula:
35. Subtract mean value of measurement with set of plates pulled up to stop from mean value of measurements under load.
36. Determine new retaining ring (1) according to following table. [Note: (Item 2) can be disregarded.]
37. Check clearance again after inserting retaining ring.

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Removing toothed belt, vehicles with old toothed belt tensioner
• Automatic gearbox 01M — Dismantling and assembling freewheel with -B1- piston
• Installing transfer box motor V253 – VW Touareg I
• Installing trim on rear bumper – VW Touran I
• 6-speed manual gearbox 02Q — Bleeding clutch system