The clutch consists of a pressure plate and a driven plate (see illustration 7.1), as well as a hydraulic drive with the main and slave cylinders (see illustrations 7.2a-b). Models with the "LuK" clutch are equipped with a self-adjusting clutch pressure plate. Replacing the pressure and driven plates separately is not permitted.
7.1 Clutch basket components "LuK" ("Sachs" - similarly)
1 2-mass flywheel, the contact surface with the clutch must be free of grooves and grease
2 Slave disk
3 Pressure disc
4 Bolt, M6 - 13 Nm, M7 - 20 Nm
7.2a External parts of the clutch hydraulic drive of the manual transmission "02Q"
1 Brake fluid reservoir
2 Spring clamp (not on all models)
3 Rubber or plastic (with gaskets on both ends) tube; do not pinch the plastic tube
4 Master cylinder
5 Tube retainer 3
6, 14 Sealing ring
7 Support
8 Clutch pedal
9 Nuts for fastening the bracket to the bulkhead, 3 pcs., 20 Nm
10 Line in the form of a tube/hose, for removal the battery and its holder must be removed
11 Tube support 10, with a diameter of 6 mm
12 Plastic line, do not pinch, battery and its holder must be removed for removal
13 Tube support 12, with a diameter of 8 mm
15 Connection for nipple 17
16 Tube/connection retainer 15
17 Bleed nipple
18 Cap
19 Executive cylinder
20 RKPP
7.2b Clutch hydraulic drive parts inside the gearbox housing "02Q"
1 Cylinder 2 mounting bolts, 3 pcs., subject to replacement, 12 Nm (for metal cylinder, without fixing sealant) or 15 Nm (for plastic cylinder, with fixing sealant)
2 Slave cylinder with release bearing, cannot be replaced separately; do not wash the bearing, just wipe it
3, 9 Sealing ring
4 Connection lock 10
5 Bleed nipple
6 Cap
7 Tube retainer 8
8 Plastic tube
10 Connection for nipple 5
11 Input shaft seal of the manual transmission
The pressure plate is bolted to the flywheel, which is connected to the engine crankshaft. Between the pressure plate and the flywheel is a driven disk, which is pressed against the flywheel by the release bearing of the slave cylinder. The driven disk is connected to the primary shaft of the manual transmission via a splined connection.
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When the clutch pedal is depressed, the brake fluid from the common reservoir is transferred under pressure through the clutch master cylinder to the slave cylinder. The slave cylinder acts on the pressure plate through the clutch release lever and the release bearing. In this case, the driven disk is moved away from the flywheel and the power connection between the engine and the manual transmission is interrupted. In the released state, the pressure spring presses the bearing against the diaphragm spring of the pressure plate. This reduces wear on the clutch release bearing, since it does not accelerate to the engine speed when engaged. No clutch drive adjustment is required.
Each time the clutch is engaged and disengaged, the friction linings of the driven disk wear out as a result of the force applied. The driven disk is a wearing part, but its average service life is quite long and depends mainly on the engine load and driving style.