5-speed manual gearbox 0A4.pdf

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
5-speed manual gearbox 0A4 - Edition 04.2010
Checking position of adjusting mechanism with new pressure
plates only
• Both edges -A- of the adjuster ring must be located between
the two notches -arrows B-.
• If the adjuster ring takes up a different position in new pressure
plates, the pressure plate and clutch plate are not allowed to
be installed.
• The adjuster ring may take up a position outside the notches
in used clutches.
Note
♦ Renew clutch plates and pressure plates with damaged or
loose rivet connections.
♦ Renew pressure plate and clutch plate together only.
♦ 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.
– 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 53) .
– Install gearbox.
52 Rep. Gr.30 - Clutch