SM 55

Service
Workshop Manual
Bora 1999 ➤ , Eos 2006 ➤ ,
Golf 1998 ➤ , Golf 2004 ➤ ,
Golf Plus 2005 ➤ , Passat 2006 ➤ ,
Polo 2002 ➤ , Sharan 1996 ➤ ,
Touran 2003 ➤
Fault finding, Power
lksw
agentransmission
AG. Volkswagen AG d
oes
n o ot g
yV ua
Edition 05.2006 rised b ran
tee
tho or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Service Department. Technical Information

Service
List of Workshop Manual wage Repair GroupsList of Workshop Manual
n G do AG. Volkswagen A
es n
Volks ot g
Repair GroupsListris of Workshop Manual Repair Groups
by ua
ed rante
ho e t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Repair Group
wit
, is n
h re
30 - Clutch
hole
spec
34 - Controls, housing
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg V0051206420

Bora 1999 ➤ , Eos 2006 ➤ , Golf 1998 ➤ , Golf 2004 ➤ , Golf Plus 2005 ...
Fault finding, Power transmission - Edition 05.2006
Contents
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Complaints regarding clutch and clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Checking clutch mechanism (slave cylinder is bolted from outside on clutch housing) . . . . 7
1.2 Checking clutch mechanism (slave cylinder is located inside clutch housing) . . . . . . . . . . 8
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Complaints regarding the selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Contents i
. Volkswagen AG
gen AG does
swa
Bora 1999 ➤ , Eos 2006 ➤ , Golf 1998 ➤ , Golf 2004y V➤ , Golf Plus 2005 ...
olk not
gu
b ara
Fault finding, Power transmission - Edition 05.2006 rised
nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ii Contents
30 – Clutch
1 Complaints regarding clutch and
clutch mechanism
Note
Checking clutch mechanism ⇒ page 7 .
Before carrying out any clutch repairs, the customer complaint

must always be checked and the cause traced. When doing this,
check whether the complaint is actually attributable to the clutch
or whether adjustment of the selector mechanism is the cause of
the problem.
The repair measures listed in this fault finding programme are to
be carried out as described in the relevant workshop manuals.
Complaint Fault description Measure
Clutch pedal does not return to orig‐ ♦ Air in line system – Bleed line system; replenish
inal position brake fluid.
AG. Volksw♦
ageLine
n AG dsystem, master or slave – Renew defective part, bleed line
agen oes
Volksw cylinder nleaking.
ot g system; replenish brake fluid.
y ua
db ran
ise
tho
r
♦ Return spring (ifteefitted)
or defec‐ – Renew return spring.
au tive. ac
ss
ce
e
nl
pt
♦ Actuator elements in bell hous‐ – Clean, lubricate bearing points.

du
an
itte
ing stiff. Repair bearing as necessary.

y li
erm
ab
ility
ot p
♦ Clutch release bearing canted – Renew guide sleeve and re‐

wit
, is n
on guide sleeve, worn. lease bearing.

h re
hole
spec
♦ Diaphragm spring of pressure – Renew pressure plate.

es, in part or in w
t to the co
plate broken.
rrectness of i
l purpos

Actuation pressure at clutch pedal ♦ Over-centre spring defective. – Renew over-centre spring.
nf
ercia
too high
orm
♦ Return spring (if fitted) too – Allocate return spring according

m
atio
m
strong, incorrect return spring. to ⇒ Electronic parts catalogue

o
n in
c
“ETKA” .
or
thi
te
sd
a
♦ Clutch release pressure in‐ – Explain situation to customer

iv
o
r
creased due to wear in clutch (release pressure rises as wear

rp
cu
o
m
f
friction linings. increases).

en
ng
t.
yi Co
op py
– Renew clutch plate if distance
t. C rig
gh ht
yri
from lining to rivet is less than
p by
o Vo
by c
0.1 mm.
lksw
cted agen
Prote AG.
♦ Actuator elements in bell hous‐ – Clean, lubricate bearing points.
ing stiff. Repair bearing bushes as nec‐
essary.
♦ Clutch release bearing canted – Renew defective parts.
on guide sleeve, worn.
♦ Contact surface of release bear‐ – Renew defective parts.

ing/release lever worn/scored.
1. Complaints regarding clutch and clutch mechanism 1


♦ Pressure plate has incorrect – Allocate according to ⇒ Elec‐
spring rating. tronic parts catalogue “ETKA” .
♦ Clutch plate stiff/sticking on – Check splines on hub for dam‐

spline. age (burrs). Renew clutch plate
as necessary.
– Clean splines of hub and input

shaft of corrosion and lubrica‐
tion deposits and lubricate with
grease -G 000 100- . Move
clutch plate back and forth, re‐
move excess grease.
Manual gearbox 02K only: – Lubricate contact points lightly
♦ Clutch push rod and release with -G 000 100- .
plate (pressure plate) stiff.
– Lubricate clutch push rod lightly.

Noises when clutch is depressed “Only Sharan:” – Clean, lubricate bearing points.
♦ Clutch pedal stiff, bearing points Repair bearing as necessary.
misaligned.
♦ Over-centre spring bearing dry,
stiff, misaligned.
♦ Return spring (if fitted) causing – Grease bearing points.

noises.
♦ Release bearing defective, – Always renew noisy release

guide for release bearing not bearings.
OK, contact surface worn.
– Renew guide sleeves if dam‐
aged.
AG. Volkswagen AG d
♦ Contact surface ksw
agen
(diaphragm o–es Renew pressure plate.
not
spring Vol
d by ends) of pressure plate gu
ara
defective
orise (bent, broken). Re‐ – Check nand,
tee if necessary, renew
ut lease bearing off-centre. release bearing and guide
h or
a a
ss sleeve. c
ce
e
nl
pt
du
– Check position of release lever.

an
itte
y li
erm
ab
– Check locating sleeves.

ility
ot p
wit
♦ Needle roller bearing in crank‐ – Renew, lubricate with MoS2

, is n
h re
shaft (if fitted) defective. Offset grease.

hole
spec
engine/gearbox.
es, in part or in w
– Check locating sleeves.

t to the co
♦ Clutch plate installed wrong way – Rectify installation position.

round.
rrectness of i
♦ Incorrect clutch plate installed. – Allocate clutch plate according

l purpos
to ⇒ Electronic parts catalogue

“ETKA” .
nform
mercia
at
om
io

n
c
in t
or
his
e
Scratching noises when engaging ♦ Air in system, clutch does not – Bleed system; check system, re‐
at
do
riv
forwards or reverse gear, selector separate fully. plenish brake fluid.

p
cum
or
mechanism sticking, catching, stiff,

f
en
ng
gear selection not possible, clutch

t.
yi Co
op
has no function C py
t. rig
gh ht
pyri by
Vo
o
2
by c lksw
cted
Rep. Gr.30 - Clutch
agen
Prote AG.

♦ Master/slave cylinder, lines – Renew defective part, top up
leaking. brake fluid, bleed system.
♦ Travel of clutch pedal insuffi‐ – Explain situation to customer.

cient (carpet, foot mat under
pedal), clutch does not fully de‐
press.
♦ Pressure plate uneven due to – Check parts, renew as necessa‐

faulty installation, clutch plate ry, observe position of centring
warped due to improper han‐ pins.
dling.
– If scratching still occurs, check
splines of clutch plate on input
shaft for ease of movement,
check needle roller bearing in
crankshaft, repair transmission
if necessary.
♦ Diaphragm spring ends broken – Renew pressure plate.
off or bent (faulty installation, re‐
lease bearing offset). – Check and, if necessary, renew
release bearing, guide sleeve.
AG. Volkswagen AG d – Check locating sleeves.
agen oes
olksw not
ed byV Manual gearbox
gu
ara 02K only – Renew push rod, check release
horis ♦ Push rod toonteshort
eo due to wear. bearing, renew as necessary.
aut ra
s c
s – Lubricate contact points of push
ce
le
rod/release bearing lightly with

un
pt
an
d
grease -G 000 100- .

itte
y li
erm
ab
♦ Clutch plate too thick. – Allocate clutch plate according

ility
ot p

wit
is n
“ETKA” .
h re
ole,
♦ Lining seized on flywheel – Lightly rub down friction surfa‐

spec
(parked up for long period, high ces of clutch linings or, in event
t to the co
level of humidity). of heavy corrosion, renew part

completely.
♦ Clutch plate stiff/sticking on – Check splines on hub for dam‐
rrectne
spline. Hub corroded, damaged age. Renew clutch plate as nec‐

during installation. Hub profile essary.
s
misaligned on one side.

s o
– Remove corrosion and deposits

cial p
f in
of grease from hub and shaft.

form
mer
Lubricate shaft lightly with

atio
grease -G 000 100- .

om
n
c
i
or
– Move clutch plate back and

thi
te
sd
a
forth, remove excess grease.

iv
o
pr
cum
r
fo
– Check position of locating

en
ng
t.
yi Co
Cop py sleeves if hub profile is mis‐
aligned.
ht. rig
rig ht
py by
co Vo
by lksw
Prote
cted AG.
agen
– Check and, if necessary, renew
release bearing, guide sleeve,
pressure plate and needle roller
bearing.
♦ Pressure plate lift insufficient – Allocate pressure plate accord‐
(incorrect pressure plate instal‐ ing to ⇒ Electronic parts cata‐
led). logue “ETKA” .


♦ Needle roller bearing in crank‐ – Renew needle roller bearing
shaft (if fitted) defective. Input and lubricate with MoS2 grease.
shaft picked up by crankshaft
when clutch is depressed. – Check locating sleeves and re‐
new if necessary.
– Check input shaft.

♦ Engine/gearbox offset exces‐ – Insert locating sleeves before in‐
sive (locating sleeves missing) stalling gearbox.
causing carrier plate of clutch
plate to bend. Needle roller – Check clutch plate, pressure
bearing in crankshaft (if fitted) plate and needle roller bearing
defective. for damage and renew as nec‐
essary.
♦ Linings flown off due excessive‐ – Renew clutch plate. Explain sit‐
ly high speed (changing down uation to customer.
when speed is too high).
♦ Linings flown off due to clutch
being allowed to slip too much
whenn Apulling
G. Volksaway.
wagen A G do
wage es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
Complaint ss Fault description Measure
ce
e
nl
Load change jolts from acceleration ♦ Assembly mounting too soft. – Explain situation to customer.
pt
du
an
itte
and abrupt reduction in engine Allocate mounting according to

y li
erm
ab
speed ⇒ Electronic parts catalogue
ility
ot p
“ETKA” , renew as necessary.

wit
, is n
♦ Lumpy engine (not running – Check, rectify engine setup.

h re
hole
smoothly).
spec
es, in part or in w
t to the co
♦ Clutch plate installed with damp‐ – Explain situation to customer.

er to prevent loose gears rat‐
tling.
rrectness of i

l purpos
shaft (if fitted) defective. Offset and lubricate with MoS2 grease.
engine/gearbox.
nform
ercia
– Check locating sleeves and re‐

new if necessary.
m
at
om
ion
c
in t
or
his
ate

do
priv
cum
or
Clutch slipping, no propulsion or ♦ Wrong clutch plate, wrong pres‐ – Allocate clutch plate and pres‐
f
en
ng
t.
yi
propulsion poor sure plate installed. sure plate according to ⇒ Elec‐
Co
op py
tronic parts catalogue “ETKA” .
t. C rig
gh ht
yri by
♦ Clutch plate worn, burnt, pres‐ – Renew clutch plate.
cop Vo
by lksw
sure plate overheated, scores,
cted agen
Prote AG.
pressure plate warped from faul‐ – Renew pressure plate.
ty installed, contact pressure of
pressure plate insufficient, driv‐ – Explain situation to customer.
ing fault, natural wear.
♦ Actuator elements on gearbox – Clean, lubricate bearing points.

stiff. Repair as necessary.
4 Rep. Gr.30 - Clutch

olkswagen AG
en AG. V
Bora 1999 ➤ , Eos 2006 ➤ , Golf 1998 ks➤
wa,g Golf 2004 ➤ , GolfdoPlus
es n 2005 ...
Vol ot g
Fault finding,
ed
by Power transmission - Edition 05.2006ua
ra
ris nte
utho eo
ra
Complaint Fault description
ss
a
Measure c
ce
le
♦ Clutch plate, pressure plate, fly‐ – Renew clutch plate.
un
pt
an
d
wheel oily. Shaft seal from en‐
itte
y li
erm
gine or gearbox defective. – Clean contact surfaces and
ab
ility
Grease on contact surfaces due pressure plate and clean fly‐
ot p
wit
to excessive greasing of hub. wheel.
is n
h re
ole,
spec
– Renew shaft seal, remove ex‐
cess grease from input shaft.
t to the co
Manual gearbox 02K only – Renew seal, clutch plate.
♦ Seal for push rod in input shaft
leaking. Bearing bush for push – Check bearing bush for push
rrectne
rod in input shaft misaligned. rod, renew as necessary.
s
– Clean pressure plate, flywheel.
s o
cial p
f i
♦ Clutch plate installed wrong way – Rectify installation, check clutch
nform
round. plate, renew as necessary.
mer
atio
om
♦ Flywheel depth too great or ex‐ – Allocate flywheel according to ⇒
n
c
i
or
n
cessive erosion on lining contact Electronic parts catalogue “ET‐
thi
te
sd
a
surface. KA” .
iv
o
pr
cum
r
fo
– Check clutch plate, pressure
en
ng
t.
yi
plate, renew as necessary.
Co
Cop py
t. rig
♦ Slave cylinder with release – Renew slave cylinder with re‐
gh ht
pyri by
bearing leaking. lease bearing.
co Vo
by lksw
cted agen
Prote AG.

Clutch jolts, ♦ Air in system – Bleed system, check brake fluid
assembly shakes level, check for leaks.
– Renew defective part.

♦ Engine not running well – Check, rectify engine setup.
♦ Driving fault, pulling away speed – Explain situation to customer.

too low.
♦ Incorrect clutch plate installed. – Allocate clutch plate according

“ETKA” .
♦ Assembly mounting too soft, – Allocate assembly mounting ac‐
misaligned. cording to ⇒ Electronic parts
catalogue “ETKA” .
♦ Clutch lining, contact surface of – Check shaft seal of gearbox in‐
pressure plate and flywheel oily put shaft or crankshaft, renew as
(oil seeping from clutch hous‐ necessary.
ing).
– Renew clutch plate, clean pres‐
sure plate and flywheel.
♦ Release bearing canted on – Renew release bearing and
guide sleeve, seized (one-sided guide sleeve.
pressure on diaphragm spring of
pressure plate). – Check actuator elements and
bearings for actuator elements.


♦ Contact surface of pressure – Check contact surface of clutch
plate has only one-sided lift due lining to flywheel, pressure plate
to canted release bearing. and diaphragm spring, renew
pressure plate as necessary.
♦ Housing of pressure plate war‐
ped during assembly. Contact – Renew release bearing and
surface of pressure plate has guide sleeve.
only one-sided lift.
♦ Input shaft has been packed – Clean grease off pressure plate
with too much grease (signs of and flywheel, renew if there are
grease on clutch plate, pressure signs of damage (rattle marks,
plate and flywheel). signs of overheating, scores).
– Remove traces of grease from

hub and shaft, lubricate shaft
lightly with grease -G 000 100- .
– Move clutch plate back and

forth, remove excess grease.
♦ Slave cylinder with release – Check threaded connections of
bearing is not flat on bell hous‐ slave cylinder to bell housing.
ing.

“Knocking” noise when depressing ♦ Slow mass/input shaft is accel‐ – Explain situation to customer.
clutch erated by abrupt clutch depres‐
gesion. Teeth
n AG. Volkswaof
genmeshed
AG do gear
wa es n
y Volks wheels strike; on clutch otplates
gu
ise
db with damper, noise is amplifiedara
nte
ut
hor
due to damper coming into con‐ eo
ss a tact. ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility

ot
wit
, is n
Noises at idle ♦ Torsional damper spring bro‐ – Renew clutch plate.

h re
hole
ken.
spec
es, in part or in w
t to the co
♦ Clutch plate installed without – Install clutch plate with damper.

damper (rattling at idle).
rrectness of i
♦ Pressure plate warped, broken, – Renew pressure plate.

unbalanced.
l purpos
♦ Lumpy engine (not running – Check engine setup, rectify as

nform
ercia
smoothly). necessary.
m
♦ Engine/gearbox offset too great – Insert locating sleeves before in‐

com
tion in
(locating sleeves missing). stalling gearbox.

r
te o
thi
s
iva
do
♦ Intermediate plate rubbing on – Mount intermediate plate on

r
rp
cum
flywheel. sealing flange and position on

fo
en
g
locating sleeves.
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.1 Checking clutch mechanism (slave cyl‐

inder is bolted from outside on clutch
housing) Volkswage es n
ot
by gu
ara
– Check if clutch is slipping. ed nte
oris eo
th
Renew clutch if necessary au ra
c
ss
ce
le
“1” The pedal return function must not be hindered by additional
un
pt
an
d
foot mats or foot mats pushed underneath.
itte
y li
rm
ab
“2” Check level of brake fluid in brake fluid reservoir
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
♦ The clutch hydraulics is connected to the brake fluid reservoir
rrectness of i
via a supply hose -arrow 1- and clip -arrow 2-.
l purpos
♦ If no or very little brake fluid is in this chamber, the system may

be leaking.
nform
ercia
“3” Check clutch hydraulics for external leaks:

m
a
com
ti
• The clutch system must be bled
on in
r
te o
thi
♦ Master cylinder
s
iva
do
r
rp
♦ Supply hose
cum
fo
en
ng
t.
♦ Line between master cylinder and slave cylinder
yi Co
Cop py
t. rig
♦ Connecting points (clip fit and threaded connections) also in
gh ht
yri by
areas that cannot be seen. cop Vo
by lksw
cted agen
Prote AG.
♦ Slave cylinder
Symptoms for external leaks are, for example, signs of fluid in or
on noise damper under gearbox.
“4” Check for correct routing of line between master cylinder and
slave cylinder. The line must not be kinked or trapped.
“5” Depress clutch pedal. To do this, the pedal must be depressed
and held over the entire pedal travel in five different positions for
approx. 20 seconds (tests different application pressures in the
hydraulic system). A second person thereby checks whether any
fluid escapes at the positions mentioned in “3”. The first position
also checks whether the clutch pedal drops on its own when pres‐
sure is maintained.
“6” Remove slave cylinder from gearbox. Do not open lines and
check boot for signs of leaking brake fluid.
Carefully pull boot off plunger -arrow-.

“7” Check function of clutch mechanism during a road test

1.2 Checking clutch mechanism (slave cyl‐

inder is located inside clutch housing)
Note
Only the bleeder -A- is visible when the slave cylinder is located
inside the clutch housing.
– Check if clutch is slipping.

Renew clutch if necessary
“1” The pedal return function must not be hindered by additional
. Volkswagen AG
foot mats or foot mats pushed underneath. swa
gen AG does
olk not
yV gu
“2” Check level of brake fluid in brake fluid reservoir
ise
db ara
nte
r
ho eo
aut ra
ss c
ce
le
Note
un
pt
an
d
itte
y li
erm
ab
♦ Note that the clutch hydraulics is connected to the brake fluid
ility
reservoir via a supply hose -arrow 1- and clip -arrow 2-.
ot p
wit
is n
♦ If no or very little brake fluid is in this chamber, the system may
h re
ole,
be leaking.
spec
t to the co
“3” Check clutch hydraulics for external leaks:
• The clutch system must be bled
rrectne
♦ Master cylinder
s
♦ Line between master cylinder and slave cylinder
s o
cial p
f in
♦ Supply hose
form
mer
♦ Connecting points (clip fit and threaded connections) also in
atio
m
areas that cannot be seen.

o
n
c
i
or
n thi
Symptoms for external leaks are, for example, signs of fluid in or
te
sd
va
on noise damper under gearbox.

i
o
pr
cum
r
fo
“4” Check for correct routing of line between master cylinder and
en
ng
t.
yi
slave cylinder. The line must not be kinked or trapped.
Co
Cop py
t. rig
gh
“5” Depress clutch pedal. To do this, the pedal must be depressed
ht
pyri by
Vo
o
and held over the entire pedal travel in five different positions for by c lksw
cted agen
approx. 20 seconds (tests different application pressures in the Prote AG.
hydraulic system). A second person thereby checks whether any

fluid escapes at the positions mentioned in “3”. The first position
also checks whether the clutch pedal drops on its own when pres‐
sure is maintained.
“6” Remove gearbox. Remove slave cylinder and check for signs
of leaking brake fluid.

Note that on some slave cylinders -A- the supply line is separate
-arrow-.
“7” Check function of clutch mechanism during a road test.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

34 – Controls, housing
1 Complaints regarding the selector
mechanism
Before carrying out any selector mechanism repairs, the custom‐
er complaint must always be checked and the cause traced.
When doing this, check whether the complaint is actually attrib‐
utable to the selector mechanism or its adjustment. It may be
necessary to check whether the complaint originates from the
clutch and clutch mechanism ⇒ page 1 .
The repair measures listed in this fault finding programme are to
be carried out as described in the relevant workshop manuals.
Scratching noises when engaging ♦ Adjustment of selector mecha‐ – Checking and rectifying.
forwards or reverse gear, selector nism.
mechanism sticking, catching, stiff,
gear selection not possible, clutch
has no function
♦ Bearing for selector level and – Grease selector mechanism, re‐
selector mechanism not lubrica‐ new defective parts.
ted, misaligned.

shaft (if fitted) defective. Input and lubricate with MoS2 grease.
shaft picked up by crankshaft
when clutch is depressed. – Check locating sleeves and re‐
new if necessary.
– Check input shaft.

♦ Synchronisation and/or selector – Repair gearbox.
mechanism in gearbox defec‐
tive. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
Complaint ss Fault description Measure c
ce
le
un
pt
“Knocking” noise when depressing ♦ Slow mass/input shaft is accel‐ – Explain situation to customer.
an
d
itte
clutch erated by abrupt clutch depres‐

y li
rm
ab
sion. Teeth of meshed gear

pe
ility
wheels strike; on clutch plates

ot
wit
, is n
with damper, noise is amplified

h re
due to damper coming into con‐

hole
spec
tact.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
10
cted agen
Prote AG.
Rep. Gr.34 - Controls, housing

SM 55

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM 55

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg V0051206420

Checking clutch mechanism ⇒ page 7 .

Before carrying out any clutch repairs, the customer complaint

♦ Actuator elements in bell hous‐ – Clean, lubricate bearing points.

ing stiff. Repair bearing as necessary.

♦ Clutch release bearing canted – Renew guide sleeve and re‐

on guide sleeve, worn. lease bearing.

♦ Diaphragm spring of pressure – Renew pressure plate.

Complaint Fault description Measure

♦ Return spring (if fitted) too – Allocate return spring according

strong, incorrect return spring. to ⇒ Electronic parts catalogue

♦ Clutch release pressure in‐ – Explain situation to customer

creased due to wear in clutch (release pressure rises as wear

friction linings. increases).

♦ Contact surface of release bear‐ – Renew defective parts.

1. Complaints regarding clutch and clutch mechanism 1

Complaint Fault description Measure

♦ Clutch plate stiff/sticking on – Check splines on hub for dam‐

– Clean splines of hub and input

Complaint Fault description Measure

♦ Return spring (if fitted) causing – Grease bearing points.

♦ Release bearing defective, – Always renew noisy release

– Check position of release lever.

– Check locating sleeves.

♦ Needle roller bearing in crank‐ – Renew, lubricate with MoS2

shaft (if fitted) defective. Offset grease.

– Check locating sleeves.

♦ Clutch plate installed wrong way – Rectify installation position.

♦ Incorrect clutch plate installed. – Allocate clutch plate according

to ⇒ Electronic parts catalogue

Complaint Fault description Measure

forwards or reverse gear, selector separate fully. plenish brake fluid.

mechanism sticking, catching, stiff,

gear selection not possible, clutch

Complaint Fault description Measure

♦ Travel of clutch pedal insuffi‐ – Explain situation to customer.

♦ Pressure plate uneven due to – Check parts, renew as necessa‐

rod/release bearing lightly with

grease -G 000 100- .

♦ Clutch plate too thick. – Allocate clutch plate according

to ⇒ Electronic parts catalogue

♦ Lining seized on flywheel – Lightly rub down friction surfa‐

level of humidity). of heavy corrosion, renew part

spline. Hub corroded, damaged age. Renew clutch plate as nec‐

misaligned on one side.

– Remove corrosion and deposits

of grease from hub and shaft.

Lubricate shaft lightly with

grease -G 000 100- .

– Move clutch plate back and

forth, remove excess grease.

– Check position of locating

1. Complaints regarding clutch and clutch mechanism 3

Complaint Fault description Measure

– Check input shaft.

and abrupt reduction in engine Allocate mounting according to

“ETKA” , renew as necessary.

♦ Lumpy engine (not running – Check, rectify engine setup.

♦ Clutch plate installed with damp‐ – Explain situation to customer.

♦ Needle roller bearing in crank‐ – Renew needle roller bearing