Clutch kit 602000700，3000943004，4005108988331 OAM198140 ，OAM198141S，VOLKITO10NOAM1981410Q DQ200， VWK2133，0AM198140B for Audi, Volkswagen, Skoda

I. Core Safety Prerequisites (Mandatory Before Installation)

• Disconnect the negative (-) battery cable. This is a standard procedure to prevent triggering the airbag or damaging electronic components during operation.

• Clutch Aligning Tool: Absolutely essential. Used to ensure the clutch disc is concentric with the flywheel; without it, the transmission will not slide into place.

• Guide Mandrel/Input Shaft Protector: Used to protect the input shaft oil seal during transmission installation.

• Torque Wrench: Must be used and properly calibrated.

• Micrometer / Depth Gauge: Used to measure pressure plate height (for certain models).

• Confirm the new kit includes: Pressure Plate (Cover), Clutch Disc, and Release Bearing.

• Note: For many Audi/Volkswagen models, it is recommended to replace the Release Fork and Guide Sleeve simultaneously, as rubber aging in these parts can cause initial launch shudder.

II. Mechanical Installation Steps (Including Critical Torque Values)

• Cleaning: After removing the old clutch, thoroughly clean the flywheel surface. Oil, rust, and hardened friction material dust must be removed.

• Inspection: Check the flywheel ring gear for cracks or broken teeth. Check the friction surface for deep grooves or heat spots (blue discoloration). If any abnormalities are found, the flywheel must be replaced; otherwise, the life of the new clutch will be extremely short.

• Locking (DMF Models): If equipped with a Dual Mass Flywheel (DMF), a specialized tool is required to lock it in the assembly position (0-point position) before installation to prevent internal spring misalignment.

• Applying Grease (Critical):

• Apply a small amount of high-temperature grease (usually included with the kit) to the splines of the clutch disc and the contact surfaces of the release bearing.

• Taboo: Never apply grease to the friction surfaces of the clutch disc!

• Installation Sequence:

• Mount the Pressure Plate onto the flywheel and hold it in place with dowel pins or by hand.

• Place the Clutch Disc in the center of the pressure plate.

• Orientation Check: Observe the clutch disc; the "Flywheel Side" (or "Gearbox Side") marking must face the correct direction. Typically, the side with the longer damper springs faces the transmission, and the shorter/flat side faces the flywheel (always refer to the kit instructions, as markings vary slightly by brand such as Luk and Sachs).

• Aligning:

• Insert the aligning tool through the clutch disc splines and into the center hole of the transmission input shaft (or the old pilot bearing bore).

• Tap the tool lightly to ensure the clutch disc is fully seated and parallel to the flywheel face.

• Standard Torque (Reference values, check specific model):

• M8 Bolts: Typically 22 - 25 N·m.

• M10 Bolts: Typically 35 - 40 N·m.

• Tightening Sequence: Must be strictly tightened in a crisscross/diagonal sequence, gradually in 2-3 stages.

• Incorrect Method: Tightening clockwise one by one (causes pressure plate distortion and shudder).

• Correct Method: Similar to the sequence used for tightening cylinder head bolts.

• Remove Tool: Once the bolts are fully tightened, remove the aligning tool.

• Install the release bearing onto the fork (if secured by a C-clip, ensure it is fully engaged).

• Apply grease to the travel path of the release bearing on the guide tube (if applicable).

I. Mechanical Installation Details (Precision Control)

• Note: For many high-performance VW/Audi models (e.g., GTI, R36) or specific model years, the pressure plate bolts require not only a torque specification (e.g., 25 N·m) but also an angle tightening procedure (e.g., an additional 90 degrees of rotation).

• Consequence: If tightened to standard torque only, the bolts may loosen under long-term high loads, causing pressure plate runout and initial launch shudder.

• Source: Always consult the specific tightening specifications in ELSA for the vehicle's VIN.

• Note: Whenever replacing the clutch, the input shaft pilot bearing must be replaced. A dry old bearing causes the transmission input shaft to rotate eccentrically.

• Lubrication: When installing the new bearing, apply Loctite 603 (retaining compound) between the bearing outer race and the crankshaft bore to prevent rattling; apply high-temperature grease inside the bearing.

• Consequence: Insufficient lubrication will result in a loud, high-pitched squeal (whistling noise).

• Common Fault: The release fork pivot on VW MQ200/MQ250 transmissions features a rubber bushing. Over time, the rubber ages and cracks.

• Requirement: Even if the fork is not replaced, it is highly recommended to replace this rubber bushing.

• Consequence: A damaged bushing causes the pivot point to loosen, making the release bearing contact the pressure plate diaphragm spring at an angle, which accelerates release bearing wear.

II. Special Taboos for DSG Dual-Clutch Models (DQ200/DQ250)

• Core: After installing a DSG clutch, the release gaps for the K1 and K2 clutches must be measured.

• Procedure: Use a micrometer to measure the diaphragm spring height and compare it to standard values. If they do not match, shims of different thicknesses must be installed.

• Consequences:

• Gap too small: Causes clutch slip and friction disc burnout.

• Gap too large: Causes incomplete clutch release, leading to difficult shifting, abnormal noise, or gear grinding.

• Note: When hoisting the transmission, strictly avoid bumping the mechatronics valve body.

• Bleeding: After installation is complete, the hydraulic system bleeding procedure must be performed via Odis/VCDS. Manual pedal pumping is insufficient for DSGs and can easily damage seals.

III. Critical Flywheel Inspections

• Procedure: Before installing a DMF, a special tool must be used to lock the primary and secondary masses in their relative position (0-point).

• Consequence: If installed without locking, a loud metal impact noise will occur during the first launch, and flywheel life will be extremely short.

• Inspection: Even if the flywheel looks undamaged, feel the surface by hand. If significant unevenness or blue spots (heat-induced annealing) are found, it must be replaced.

• Consequence: Pairing a new disc with an old flywheel results in insufficient contact area, making slip highly likely.

I. Volkswagen Group OEM Core Sources (ELSA/ErWin)

• Search Path: Enter VIN → Workshop Manuals → Power Transmission → Manual Gearbox / Dual Clutch Gearbox → Clutch → Removal and Installation; Torque parameters found in Technical Specifications / Assembly Instructions.

• Core Content: Pressure plate bolt "Torque + Angle" (e.g., 25 N·m + 90°), DMF locking specifications, DQ200/DQ250 gap adjustment, pilot bearing replacement and Loctite 603 requirements, release fork bushing replacement standards.

• Access: Volkswagen Group ELSA/ErWin official subscription, authorized dealer DMS systems, or model-specific physical manuals.

• Applicable Topics: Cases involving shudder after clutch installation, release bearing noise, DSG hydraulic system bleeding, and mechatronics adaptation failures.

• Supplementary Points: Includes aging checks for MQ200/MQ250 release fork rubber bushings, DQ200 clutch gap shim selection tables, and DMF thermal deformation judgment standards.

• Access: Authorized dealer technical departments, third-party repair databases (e.g., Alldata, Mitchell1).

• Search Path: TSB Database → Search for keywords like "Clutch Installation," "Clutch Chatter," or "DSG Clutch Gap Adjustment."

II. Component Manufacturer Specifications (Luk/Sachs/Denso)

• Key Positioning Points: Includes friction disc orientation markings, spline lubrication "No-Go/Special Zones," pressure plate aligning tool models, DSG adjustment shim thickness matching tables, and release bearing lubrication specifications.

• Access: Brand official website technical support pages, authorized dealer technical documentation.

• Search Path: Luk/Sachs Service Guide → Clutch Kit Installation → Mechanical/Electrical Checks.

• Core Parameters: Release bearing insulation resistance, high-temperature grease model numbers, guide sleeve fit clearances, etc.