Volkswagen Workshop Service and Repair Manuals

Installing and adjusting clutch   Caution Avoid removing or lifting plate carriers because the plates could turn. Brief description l  Turn gearbox to vertical in repair stand so that it is possible adjust axial play of clutch without error. l  Clamp gearbox firmly in support clamp -VW 313- or engine and gearbox support -VAS 6095- and do not twist → Chapter. l  Make sure that large plate carrier has not slipped out of lowest plate. l  Pump shaft of oil pump must be removed. l  Do not install corrugated retaining rings. Special tools and workshop equipment required

t  Retaining pin -T10303-

–  Set retaining pin -T10303- on seat of cover.

–  Insert clutch.

–  Retaining pin -T10303- should be held by a second mechanic in the process.

–  Carefully remove clutch cover from clutch and lay it to side.   Caution Avoid removing or lifting plate carriers because the plates could turn.

–  Select 2 mm retaining ring from among the rings supplied and install it temporarily. Take 2 measurements before removing the ring: First measurement l  Retaining pin -T10303- remains on seat of cover. –  Screw universal dial gauge -VW 387- to gearbox flange.

–  Set tip of dial gauge on input shaft –  Set dial gauge to 0 with preload. –  Raise clutch to stop and note result of measurement. Second measurement l  Retaining pin -T10303- remains on seat of cover.

–  Set tip of dial gauge on hub of large plate carrier.   Note Tip must not sit on retaining ring. –  Set dial gauge to 0 with preload again. –  Raise clutch to stop again and also note this result. –  Calculate definitive ring to be installed using following formula:    Second measurement - first measurement + 1.85 mm = thickness of ring to be installed –  Note down result. The remaining 9 retaining rings are in increments of 0.1 millimetre. –  Measure all rings and determine which ring is closest to your result. –  Remove 2 mm ring and install calculated ring. –  Dispose of all remaining rings and 2 mm ring.   Note Without exception, retaining rings may be installed only once.

–  Insert pump shaft.

–  Install clutch cover so that lug aligns with marking. –  Remove retaining pin -T10303-. –  Install cover (end cover) → Chapter. –  After installing gearbox, perform basic measurement of mechatronic unit for dual clutch gearbox -J743-. Special care The assembly of the multi-clutch requires special care because all components have been balanced together during manufacture. If parts are turned relative to each other, imbalances result which reduce ease of shifting and service life. If parts of clutch have slipped out or plate carriers have been lifted, the large plate carrier as well as the small one can be threaded into all inner plates by hand with gentle turning movements. The clutch cover should always be installed in the same position as was the case in the delivery of the new clutch → Fig..

1 -	Multi-clutch housing

2 -

Seal

q

Qty. 4

3 -	Large plate carrier

q	Do not remove

Caution Avoid removing or lifting plate carrier. Not even a little bit! The plates could turn.

4 -	Outer plate

q

Qty. 4

5 -	Inner plate

q

Qty. 4

6 -	Thrust washer

7 -	Retaining ring

q	Always renew

q	Do not install corrugated retaining rings

8 -	Retaining ring

q	Measure again every time the clutch is installed

9 -	Clutch cover

10 -	Retaining ring

q	Always renew

q	Do not install corrugated retaining rings