Attention. During operation of the clutch, friction linings wear out, resulting in the formation of dust containing asbestos, which is harmful to health, therefore, when cleaning the clutch, do not use compressed air or inhale dust. Cleaning of clutch parts from dust must be done using brake fluid or methyl alcohol. After cleaning the parts, wipe them dry.
Withdrawal
Remove the gearbox.
Use a marker or paint to mark the position of the pressure plate in relation to the flywheel.
Using the AUDI 3067 special tool or a screwdriver, use the teeth of the flywheel ring gear to block the flywheel from turning (see fig. 5.4).
Gradually loosen the pressure plate mounting bolts diagonally by turning each bolt 1 or ½ turns until the diaphragm spring stops acting, and unscrew the bolts.
Remove the pressure plate, while protecting the drive plate from falling.
Wipe the clutch release bearing, but do not wash it in solvent.
Wipe flywheel.
Examination
Check the condition of the clutch pressure plate. The wear marks at the ends of the pressure spring should be half the thickness of the material from which the spring is made (see fig. 5.5).
Check the tightness of the rivet connection between the pressure plate and the housing.
Check the pressure plate for cracks, burn marks and surface wear. Using a steel ruler and feeler gauge, check the flatness of the working surface of the pressure plate. Flatness deviation should be less than 0.2mm (see fig. 5.6).
Check the condition of the friction surface of the flywheel for cracks, burn marks and surface wear.
Check the condition of the friction linings of the drive disc and if there are traces of oil or mechanical damage on them, replace the disc.
Measure the thickness of the drive disc linings. If their thickness is less than acceptable or if the rivet heads are close to the work surface, replace them or the disk.
Check the end runout of the drive plate, which should be less than 0.8 mm at a distance of 2.5 mm from the outer diameter.
Check the condition of the clutch release bearing, which should rotate easily, evenly and silently, and there should be no play in it. The working surface of the bearing acting on the diaphragm spring must not have defects (see fig. 5.7).
The serviceability of the clutch release bearing can be determined without removing it from the car, for which it is necessary to press the clutch pedal with the engine running. If there is additional noise when you press the clutch pedal, then the bearing is defective and needs to be replaced.
Installation
Attention. If the clutch drive disc was replaced, the friction linings of which were burnt due to overloads, it is first necessary to check the condition of the mating surfaces of the flywheel and pressure plate.
When installing a new clutch drive or pressure plate, remove the anti-corrosion protection from them.
When installing the drive plate, make sure that oil does not get on its friction linings, even in small quantities. Before installing the drive plate, clean the mating surface of the flywheel and pressure plate with a clean rag, and install the drive plate with clean hands.
Apply a light coat of molybdenum disulphide grease or AUDI G000100 to the splines in the drive disc hub. Install the drive plate on the input shaft of the gearbox and move it back and forth along the shaft until it starts to move easily. Remove the drive disc from the input shaft and wipe off excess grease from the disc and shaft.
Install the drive plate onto the pressure plate with the protrusion of the clutch disc hub pointing towards the pressure plate. If there are marks on the drive plate, they must be on the side opposite the pressure plate (see fig. 5.8).
Using the HAZET-2174 or AUDI-3176 special drift, center and secure the drive plate on the pressure plate (see fig. 5.8).
Install the drive and pressure plate on the flywheel guide pins.
When installing the pressure plate on models with V6 engines, except for the 2.4-I engine, align the marks on the flywheel and the pressure plate housing (see fig. 5.2).
Bolt the pressure plate housing to the flywheel, while tightening the bolts diagonally, turning each bolt 1 or ½ turns until the pressure plate housing is firmly pressed against the flywheel, then tighten the bolts to 25 Nm.
Remove the mandrel centering the driven disk.
Lubricate the clutch release bearing guide bushing with a thin coat of special grease based on molybdenum disulphide.
Install the gearbox.
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