Clutch kit 03G105264C 835035 03G105266BA 03G105264D 835035，ADT330250， ADV183059 03L105266BS 03G105266AC ECSK004 EC112 for Volkswagen Golf 4 Touran Passat 3c2

I. Preparation and Tools

• Clutch Alignment Tool: This is the most critical tool. It ensures the pressure plate and friction disc are concentric; without it, the transmission input shaft cannot be installed.

• Torque Wrench: Mandatory for tightening the pressure plate and flywheel bolts to specification.

• Puller/Separator: Used to separate the transmission from the engine.

• Jack and Safety Stands: To ensure the vehicle is secure.

• Clutch Disc (Friction Plate)

• Pressure Plate (Clutch Cover)

• Release Bearing (some models use a Concentric Slave Cylinder / CSC)

• Pilot Bearing (installed in the end of the crankshaft)

II. Removal Steps

1. Disconnect the Negative Battery Terminal: To prevent short circuits.

2. Remove the Transmission:

• Lift the vehicle and remove the front wheels.

• Remove the drive shafts (CV joints), taking care with the dust boots.

• Remove the transmission mount, shift linkage/cables, starter motor, and clutch slave cylinder (if externally mounted).

• Support the engine, remove all bolts connecting the transmission to the engine, and pull the transmission rearward to separate it.

3. Remove the Old Clutch:

• Use an air impact wrench or socket wrench to remove the pressure plate bolts (Note: Loosen bolts diagonally to prevent pressure plate distortion).

• Remove the pressure plate and old friction disc.

• Inspect the Flywheel: If the ring gear is worn, the surface has deep grooves, or it is warped, replacement or "resurfacing" is recommended.

III. Installation Steps (Core Process)

1. Cleaning and Lubrication

• Cleaning: Thoroughly clean the flywheel surface and pressure plate contact surface using carburetor cleaner or brake cleaner. Ensure no oil residue or rust remains.

• Lubrication:

• Apply a small amount of high-temperature grease inside the guide sleeve of the release bearing.

• Apply a small amount of lubricating oil (or specialized Molykote grease) to the splines of the transmission input shaft.

• Warning: Never allow grease to contact the friction surfaces of the clutch disc or flywheel, as this will cause slipping.

2. Install Pilot Bearing (if applicable)

• If the pilot bearing in the crankshaft is seized or worn, it must be replaced. Use a specialized drift to tap the new bearing into place.

3. Install Clutch Disc and Pressure Plate (Critical Step)

• Position Pressure Plate: Mount the new pressure plate onto the flywheel. Do not fully tighten the bolts yet.

• Position Friction Disc: Place the friction disc in the center of the pressure plate.

• Identify Direction: Check for markings on the disc. Look for "Flywheel Side" or "Gearbox Side". If unmarked, the general rule is: the side with the longer damper springs faces the transmission, and the shorter/flat side faces the flywheel.

• Align the Splines (The Most Difficult Part):

• VW General Torque Reference: Typically 20-25 Nm (Always consult the repair manual for specifics; e.g., Passat B5 is usually 22Nm).

• Insert the alignment tool through the friction disc and into the pilot bearing at the end of the crankshaft.

• Press down gently to ensure the friction disc is centered and the tool rotates smoothly.

• Secure Pressure Plate: Hold the tool in place and use a torque wrench to tighten the pressure plate bolts in a diagonal/crisscross pattern.

• Remove Tool: Once bolts are tight, remove the alignment tool.

4. Install Release Bearing

• Mechanical Cable Type: Hang the release bearing on the release fork and apply grease.

• Hydraulic Type (CSC): For models like the Passat and Golf 6/7, the release bearing is often integrated into the transmission or requires pressing in. Ensure the pushrod makes good contact with the pressure plate diaphragm spring.

IV. Transmission Reinstallation and Commissioning

1. Install Transmission:

• Ensure the transmission input shaft splines are lubricated.

• Push the transmission into place smoothly. If resistance is felt, do not use brute force or hammering. This indicates the clutch disc is misaligned; you must remove and realign it.

2. Tighten Bolts:

• Tighten the engine-to-transmission bolts to specification (usually 40-50 Nm + 90 degrees).

• Reinstall the starter motor, shift mechanism, drive shafts, etc.

3. Bleeding (if applicable):

• If equipped with a hydraulic clutch system, the slave cylinder needs bleeding after installation. Pump the clutch pedal until firm resistance is felt.

I. Hardware Inspection (Don't just replace the "Clutch Kit")

• Symptoms: Volkswagen 1.8T and 2.0T engines (especially in Passat and high-performance Golf models) commonly use DMFs. Symptoms include a "clunking" noise when starting or excessive free play felt when shaking the outer ring of the flywheel by hand.

• Precautions: Must be replaced. If only the clutch disc is replaced without fixing a damaged flywheel, the new disc will wear rapidly due to flywheel oscillation, causing shudder during take-off and recurring noise.

• Recommendation: For best results, replace with OEM parts. For budget constraints, consider converting to a "Single Mass Flywheel" (requires ECU remapping and will increase NVH/vibration).

• Location: A small bearing hidden in the center of the crankshaft flange.

• Precautions: Must be replaced. Although this bearing is inexpensive, if it seizes, it can shear off the transmission input shaft. Many workshops skip this step to save time; ensure you supervise this replacement.

• VW models use either cable-operated or hydraulic (CSC - Concentric Slave Cylinder) types.

• Precautions: If it is a hydraulic bearing (usually installed inside the transmission), check the seals for integrity before installation. Ensure the hydraulic line fitting is not damaged during installation, as leaks after assembly are very troublesome to fix.

II. Installation Details (Determines if Re-work is Needed)

• How to Determine:

• Check Markings: The disc is usually stamped with "Flywheel Side" or "Gearbox Side".

• Check Rivets/Springs: If unmarked, the side with the longer, protruding damper springs faces the transmission; the side with deeper rivets and a flatter surface faces the flywheel.

• Consequences: The clutch housing space in Touran and Passat models is compact. If installed backwards, the transmission cannot be pushed in. Forcing it will break the damper springs.

• Precautions: Do not rely on a technician's "feel". Before tightening the pressure plate bolts, the alignment tool (dummy shaft) must be inserted.

• Standard: The tool must rotate freely and slide up and down smoothly, indicating the disc splines are perfectly concentric with the crankshaft pilot bearing. If the tool binds, the transmission input shaft will jam against the disc splines, preventing installation.

• Precautions: Strictly prohibit tightening bolts clockwise one by one.

• Procedure: Must be tightened in a crisscross (diagonal) sequence in 2-3 stages. For example: first to 10Nm each, second to the specified torque (usually 22Nm-25Nm).

• Consequences: Tightening all at once in sequence will deform the pressure plate, causing uneven engagement and shudder during take-off.

• References：
  

• Source of This Information
• You asked about the source of the content regarding the "Clutch Kit Installation Methods and Precautions for Volkswagen Golf, Touran, and Passat." This content originates from the historical replies within this conversation (i.e., the original content compiled for you by me), and is not copied from any public webpage or official manual.
• Here is a detailed explanation:

• Content Source and Basis

• Original Compilation: This content is a synthesis based on the general repair logic of transverse engine manual transmissions found in Volkswagen's PQ/MQB platforms. It references Volkswagen's official repair manuals (such as the ETKA and Erwin systems), professional repair experience, and industry-standard specifications. It is a compiled practical guide and does not correspond to a single original text from a public webpage.

• Core Reference Materials

• Volkswagen Official Repair Manuals: (e.g., the disassembly and assembly chapters for specific chassis/transmissions of the Golf, Passat, and Touran), which include torque specifications and requirements for special tools.

• General Automotive Repair Industry Standards: Such as specifications for clutch centering, diagonal tightening of pressure plate bolts, and determining friction disc orientation.

• Summary of Common Repair Cases: Including easily overlooked points such as Dual Mass Flywheel (DMF) inspection and pilot bearing replacement.

• Non-Public Source Annotation

• The content contains no citations of third-party links or literature. It is an integrated output of repair experience specific to these vehicle models and is intended for technical reference within this conversation only.