Removing and installing clutch in conjunction with Sachs dual-mass flywheel — VW

🧭 Before you start

Fits: platform code 138

Don't miss

• Check spring connections between pressure plate and cover for cracks and make sure rivet fastenings are seated tightly.
• Disregard arrows (A) and (B).
• Make sure that stop pin (position setter) (arrow) can be moved easily.

🔧 Engine codes this applies to

📐 75 workshop diagrams for CDLA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove gearbox .
2. Use counterhold3067 to loosen bolts.
3. Loosen all bolts in small steps and diagonally.
4. If stop does not loosen, push pin in direction of dual-mass flywheel.
5. Remove pressure plate and clutch plate. [Note: Select clutch pressure plate and pressure plate according to engine code and Electronic Parts Catalogue.Clean input shaft splines and, on used clutch plate, hub splines. Remove corrosion and apply a very thin coat of clutch plate spline greaseG 000 100 to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.Clutch pressure plates are protected against corrosion and greased. Except for the friction surface contacting the clutch plate, the clutch pressure plate must not be cleaned. The service life of the clutch will otherwise be shortened considerably.The friction surface of the clutch pressure plate and the flywheel must be cleaned (degreased) thoroughly.If the clutch has burnt out, thoroughly clean the gearbox housing in the area of the clutch and parts of the engine facing the gearbox in order to reduce the smell of burnt linings.Blow off dual-mass flywheel with compressed air only.The clutch plate linings must make full contact with flywheel and the friction surface of the clutch pressure plate. Only then insert securing bolts.Tighten securing bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of flywheel.Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.]

6. Check spring connections between pressure plate and cover for cracks and make sure rivet fastenings are seated tightly.
7. Use counterhold tool3067 when installing. [Note: Disregard arrows (A) and (B).]
8. Make sure that stop pin (position setter) (arrow) can be moved easily.
9. Push pressure plate onto centring pins.
10. Tighten all bolts evenly by hand until bolt heads contact pressure plate.
11. Tighten all bolts diagonally and in small steps.
12. Installing gearbox .

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