Volkswagen Workshop Service and Repair Manuals

Removing dual clutch

Special tools and workshop equipment required

t	Hook -3438-

t	Engine plug set -VAS 6122-

t	Support device -T10323-

t	-T10356/5- from assembly tool -T10356-

t	Puller -T10373-

t	Thrust piece -T10376-

Requirement: l  Gearbox removed and secured to engine and gearbox jack → Chapter. l  Mechatronic unit for dual clutch gearbox -J743- built into gearbox.

–  Pull off both breather caps -arrows- and close using clean plugs from engine bung set -VAS 6122- to achieve an oil-tight seal.   WARNING The breather cap on the mechatronic unit is destroyed during removal and must be renewed.

–  Turn gearbox on engine and gearbox jack upwards together with clutch..   Note The clutch is pulled off upwards. The mechatronic unit remains on the gearbox.

–  Remove retaining ring of hub -arrow-.

–  Remove hub with hook -3438- and a screwdriver.   Note If parts of clutch are renewed, the position of engagement bearings „K 1“ and „K 2“ must be set later. It is therefore advisable to determine dimension „B“ for the measurements now → Chapter.

–  Remove retaining ring -arrow- for clutch . If retaining ring cannot be removed:   Note t  If the retaining ring cannot be removed it is because the clutch has »clamped« the retaining ring at the bottom. t  In this case, push the clutch down slightly (see following description) and release the load on the retaining ring. Never strike the clutch or shaft with a hammer!

–  Position support bracket -T10323- parallel to gearbox flange as shown in illustration. –  If necessary, balance out gaps using -T10356/5-, for example. –  Screw in bolts -A- hand-tight.   Note Bolts -A-, secure with nut as required.   Caution Risk of damage to clutch and other components! Push down clutch using only very light force. –  To press down, turn spindle against thrust piece -T10376-.

–  Remove retaining ring -arrow- for clutch.   WARNING It is not permissible to reuse the retaining ring.

Continuation once retaining ring has been removed: –  Insert puller -T10373- into clutch and bore out clutch.

–  Remove clutch together with puller -T10373-.

–  Remove »large« engaging lever with »small« engagement bearing.   Note The upper part of guide sleeve cannot be removed or installed separately. It is always removed and installed together with lower part of guide sleeve and »small« engagement lever.

–  Undo and remove bolts and remove »small« engagement lever together with upper and lower parts of guide sleeve.

If no parts are renewed, the ball stud -2- remains installed. The hinge mounting -1- is not removed.   Note If dimension „B“ has already been determined, it is now possible to proceed with step „2“ of the measurement → Anchor