Clutch Assembly: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE: Before installing transmission, press clutch release lever toward transmission housing and secure it with an assembly pin, assembly bolt or a M 8 X 35 bolt. Remove pin or bolt after transmission has been installed. Hole will then be sealed by 3rd cable support bracket securing bolt. See Fig 1.

Fig 1: Securing Clutch Release Lever

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To install, reverse removal procedure. Clean input shaft splines and on used clutch plates, the hub splines. Remove corrosion and apply only a very thin coating of grease Part No: G 000 100 to the input shaft splines. Then move clutch plate back and forth on input shaft until hub moves freely. Excess grease must be removed.
On models with dual mass flywheel, installed position of clutch disc have a shorter hub end pointing toward pressure plate. On models with single piece flywheel, installed position of clutch disc spring cage faces pressure plate.
Apply grease to ball stud and inner surface of release bearing.
Install pressure plate bolts finger tight. Using clutch centering tool (3190A), align clutch disc and pilot bushing holes. See Fig 2. Pressure plate contact surface and clutch plate must make full contact with flywheel. Tighten bolts diagonally and evenly to prevent damage to the centering holes in the pressure plate housing and the centering pins in the flywheel. See TORQUE SPECIFICATIONS .

Fig 2: Aligning Clutch Disc
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Using flywheel lock (3067) or similar device, hold crankshaft from turning. Tighten flywheel bolts to specification. See TORQUE SPECIFICATIONS . Ensure transmission oil level is correct.