5-speed manual gearbox 0A4.pdf

Checking ends of diaphragm spring
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0A4 - Edition 04.2010
• Wear to half the thickness of the diaphragm spring -arrows- is
permitted.
Checking spring connections and riveted connections
– Check spring connections between thrust plate and cover for
cracks and make sure rivet fastenings are seated tightly.
Note
♦ Renew clutch plates and pressure plates with damaged or
loose rivet connections.
♦ Always renew pressure plate and clutch plate together.
♦ Select clutch plate and pressure plate according to engine
code and ⇒ Electronic parts catalogue “ETKA” .
♦ If clutch has burnt out, thoroughly clean clutch housing, flywheel
and parts of engine facing gearbox to reduce smell of
burnt linings.
♦ Clean input shaft splines and, on used clutch plate, hub
splines. Remove corrosion and apply only a very thin coat of
clutch plate spline grease -G 000 100- to splines. Then move
clutch plate to and fro on input shaft until hub moves freely on
shaft. Remove excessive grease.
♦ Pressure plates are protected against corrosion and greased.
Clean contact surface only. Otherwise, the service life of the
clutch will be considerably reduced.
♦ Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert securing bolts.
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in this document. Copyright by Volkswagen AG.
– Reverse position of counterhold tool -3067- when installing.
– Put pressure plate onto centring pins.
– To centre clutch plate, use centring mandrel -3190 A- .
– Tighten all bolts evenly by hand until bolt heads contact pressure
plate.
– Tighten bolts in small steps diagonally in order not to damage
centring holes of pressure plate and centring pins of dualmass
flywheel.
Torque setting: ⇒ Item 4 (page 50) .
– Install gearbox.
4. Repairing clutch, in conjunction with dual-mass flywheel 49