Skoda Workshop Service and Repair Manuals

Adjust the position of the engaging bearings for clutch „K 1 and K 2“ - „new design“ as of 06.11 Special tools and workshop equipment required t  Gauge block -T10466- t  Straightedge -T40100- t  Digital depth gauge The position of the engaging lever must be adjusted if: t  The clutch was replaced t  The engaging levers were replaced t  The ball stud for „K2“ was replaced t  The engaging bearing was replaced. If all the mentioned parts are only removed and reinstalled, there is nothing to adjust. Conditions l  Only use proper tools. l  The flange of the clutch housing must be free of »irregularities«. This ensures a good position of the straightedge. l  The mechatronics is installed. Short description The position of the engaging bearing is comparable with the clutch play of a mechanical manual gearbox. In the automatic gearbox DSG - 0AM, there are tolerances in the engaging system of the gearbox and in the gearbox itself. Tolerances also exist inside the double clutch. These tolerances must be considered separately when adjusting. In the following procedure is first shown how to establish all the necessary dimensions on the »gearbox side« in order to determine the suitable adjusting washer. The tolerances on the gearbox side and the tolerances in the clutch determine the thickness of the adjusting washer. Overview of clutch control:

1 -	Adjusting washer for „K1“

q	Determine thickness → Chapter

2 -	Large engaging lever for „K1“

q	together with large engaging bearing

3 -	Hinge bearing

q	for large engaging lever Pos. 2

q	is not replaced

4 -	Small engaging bearing for „K2“

5 -	Adjusting washer for „K2“

q	Determine thickness → Chapter

6 -	Guide bushing-top part

q	for small engaging lever Pos. 7

q	is removed and installed together with the guide bushing-bottom part Pos. 7

7 -	Small engaging lever for „K2“

q	is removed and installed together with the top and bottom part of the guide bushing

8 -

Ball pin

q	for small engaging lever Pos. 7

9 -	Screw, 8 Nm + torque a further 90° (1/4 turn)

q

replace

10 -	Guide bushing-bottom part

q	for small engaging lever Pos. 7

q	is removed and installed together with the guide bushing-top part Pos. 6

Adjust the position of the engaging bearings for clutch „K 1 and K 2“

First the dimension „B“ must be determined. This dimension is required for both clutches »K 1« and »K 2«.   Note Perform the following work steps accurately and »in sequence«. Setting

–  Remove ball stud.

–  Install a new ball stud.   Note Press in the ball stud by hand, if necessary slightly drive in with a plastic hammer (in order not to damage the ball stud).

–  Install the old circlip of the outer drive shaft -arrow-.

–  Place the ruler -T40100- upright on the flange of the clutch housing.   Note The measuring ruler -T40100- must remain in this position during the following measurements. Do not turn or remove it.

–  Place the digital depth gauge-A- on the outer drive shaft -B-. –  Reset the depth gauge to »zero«.

–  Measure the distance to the circlip. –  Note the result and name it „B“ = 2.62 mm.

–  Measure the dimension „B“ once more at the opposite-facing point. –  Note the result and name it „B2“ = 2.58 mm.   Note Do not measure on the joint of the ring. The ring could be pressed off from the joint and thus the measuring result will be inaccurate. –  Determine the mean value from both measurement results. Example:    Dimension „B“ = B1+B2 2 = 2,62+2,58 2 = 2.60 This dimension „B“ is required for the following calculations. In the following example calculations „B“ should be = 2.60 mm. The dimension „B“ is for this example, there can be another value „B“ for a different gearbox. As there are 2 clutches, 2 steps are performed for the adjustment. Each measurement requires different preparatory measures, including a few calculations. Please observe the following work procedures.

–  Remove the circlip -arrow- again.   Note This ring must not be reinstalled!

Determine the dimension „A1“ of the adjusting washer for the large engaging bearing of clutch „K1“.   WARNING Do not insert an adjusting washer!

–  Insert the large engaging lever.

–  Position the gauge block -T10466- on the »large« engaging bearing. –  Press on the gauge block -T10466- once and turn it at the same time. In this way one can observe how the engaging bearing turns. Thus, the gauge block -T10466- is also »positioned« correctly on the bearing.

–  Position the digital depth gauge at the »top« on the outer drive shaft and set the digital depth gauge to „0“. The ruler -T40100- is already positioned »upright« on the flange of the clutch housing → Anchor.

–  Measure the distance from the »shaft end« to the gauge block -T10466-.

–  Position the digital depth gauge twice at opposite-facing points for a precise measurement. In this way, an even more precise value is determined as the inaccuracy resulting from the »wobbling« on the engaging bearing is thus minimised. –  Calculate the mean value „A1“ of both measurements to the gauge block -T10466-. –  Note this value and name it „A1“. Example:    Dimension „A1“ = 4,93+4,91 2 = 4.92 Result: „A1“ = 4.92 mm The following calculation: „A1“ minus „B“ = depth of the engaging bearing for clutch „K1“. Example calculation: 4,92 mm minus 2.60 mm = 2,32 mm. You have now determined the value of how deep the engaging bearing is actually positioned in the gearbox. –  Continue the calculation: Example calculation: Now the tolerances in the double clutch must be included in this calculation. This is a very simple procedure:

–  Please read off the value of the clutch tolerance -arrow- from the »new« clutch. A value between minus 0.40 and plus 0.40 mm is marked on the new clutch. –  Note this value. Example: „+0.0 mm“ is given on the clutch K1. The last calculation for »K 1«: »its determined« air passage plus the value of the clutch = thickness of adjusting washer for »K1« Example calculation: 2,32 mm + 0.0 = 2,32 mm. Result: thickness of the adjusting washer for »K1« = 2.32 –  Select the correct washer from the table and put it aside until you are ready to install it.

Determined thickness of the adjusting washer mm	Available adjusting washers thickness in mm	Part number
1,21...1,60	1,50	0AM 141 383
1,61...1,80	1,70	0AM 141 383 A
1,81...2,00	1,90	0AM 141 383 B
2,01...2,20	2,10	0AM 141 383 C
2,21...2,40	2,30	0AM 141 383 D
2,41...2,60	2,50	0AM 141 383 E
2,61...2,80	2,70	0AM 141 383 F
2,81...3,00	2,90	0AM 141 383 G
3,01...3,20	3,10	0AM 141 383 H
3,21...3,40	3,30	0AM 141 383 J
3,41...3,80	3,50	0AM 141 383 K

–  From the delivered washers, determine the required adjusting washer and put it aside until you are ready to install it. In this case, the adjusting washer of 2.30 mm, part number 0AM 141 383 D is installed.   WARNING At a later stage, just insert this 1 adjusting washer. Do not insert 2 washers. Thus, the »correct« adjusting washer for „K 1“ is determined. Please install this adjusting washer when installing the clutch at a later stage. –  Proceed with the adjustment for the clutch „K 2“.

Determine the dimension „A2“ of the adjusting washer for the small engaging bearing of clutch „K2“.

–  Remove the large engaging lever.

–  Insert the small engaging lever with the top and bottom part of the guide bushing. Tighten screws to tightening torque → Chapter.

–  Only insert the small bearing without adjusting washer.   WARNING Do not insert an adjusting washer!

The small engaging bearing fits in only one position due to the 8 grooves. –  While »turning«, check if the small engaging bearing is correctly installed and the grooves are correctly positioned.

–  Position the gauge block -T10466- on the small engaging bearing. –  Press on the gauge block -T10466- once and turn it at the same time. In this way one can observe how the engaging bearing turns. Thus, the gauge block -T10466- is also »positioned« correctly on the bearing.

–  Place the digital depth gauge at the »top« on the outer drive shaft. –  Set the depth gauge to »0«.

–  Measure the distance from the »shaft end« to the gauge block -T10466-.

–  Position the digital depth gauge twice at opposite-facing points for a precise measurement. In this way, an even more precise value is determined as the inaccuracy resulting from the »wobbling« on the engaging bearing is thus minimised. –  Calculate the mean value of both measurements to the gauge block -T10466-. –  Note this value and name it „A2“. Example:    Dimension „A2“ = 4,79 + 4,75 2 = 4.77 Result: „A2“ = 4.77 mm The following calculation: „A2“ minus „B“ = depth of the engaging bearing for clutch „K2“. Example calculation: 4.77 mm minus 2.60 mm = 2.17 mm. You have now determined the value of how deep the engaging bearing is actually positioned in the gearbox. –  Continue the calculation: Example calculation: Now the tolerances in the double clutch must be included in this calculation. This is a very simple procedure:

–  Please read off the value of the clutch tolerance -arrow- from the »new« clutch. A value between minus 0.40 and plus 0.40 mm is marked on the new clutch. –  Note this value. Example: „+0.4 mm“ is given on the clutch K2. The last calculation for »K 2«: »its determined« air passage plus the value of the clutch = thickness of adjusting washer for »K2« Example calculation: 2.17 mm + 0.4 = 2.57 mm. Result: thickness of the adjusting washer for »K2« = 2.57 –  Select the correct washer from the table and put it aside until you are ready to install it.

Determined thickness of the washer		Available adjusting washers thickness in mm
from	to
0,31	0,90	0,8
0,91	1,10	1,0
1,11	1,30	1,2
1,31	1,50	1,4
1,51	1,70	1,6
1,71	1,90	1,8
1,91	2,10	2,0
2,11	2,30	2,2
2,31	2,50	2,4
2,51	2,70	2,6
2,71	3,30	2,8

Thus, the »correct« adjusting washer for „K2“ is also determined. Please install this adjusting washer when installing the clutch at a later stage.

–  From the delivered washers, determine the required adjusting washer and put it aside until you are ready to install it. In this case, an adjusting washer of 2.60 mm is installed.   WARNING At a later stage, just insert this 1 adjusting washer. Do not insert 2 washers. –  The clutch can be installed → Chapter.