Volkswagen Workshop Service and Repair Manuals

Adjusting position of clutch engagement bearings „K 1“ and „K 2“ The position of the engagement bearings must be adjusted after the following tasks: t  Clutch has been renewed. t  Engaging levers have been renewed. t  Small ball stud for engaging lever „K 2“ has been renewed. t  Engagement bearings have been renewed.   Note t  There is no need to adjust anything if all the named parts have only been removed and reinstalled. t  The retaining ring must be renewed in each case. Brief description t  Position of engagement bearings is comparable with clutch play of a manual gearbox. In the 7-speed dual clutch gearbox 0AM there are tolerances in the engagement system of the gearbox and in the gearbox itself. Even within the dual clutch there are tolerances. These tolerances must be taken into account separately during adjustment. t  The following procedure first describes how to measure all necessary dimensions on the gearbox so that the appropriate shim can be selected. In addition are the tolerances in the clutch that the manufacturer has already calculated. Tolerances on gearbox and tolerances in clutch determine thickness of shim. t  Adhere to the sequence of work steps.

Overview of clutch actuation:

1 -	Shim for „K 1“

q	→ Chapter „Adjusting position of clutch engagement bearings K 1 and K 2“

2 -	Large engaging lever for „K 1“

q	With engagement bearing

3 -	Hinge mounting

q	For large engaging lever „K 1“

q	Is not renewed

4 -	Small engagement bearings for „K 2“

5 -	Shim for „K 2“

q	→ Chapter „Adjusting position of clutch engagement bearings K 1 and K 2“

6 -	Upper part of guide sleeve

q	Small small engaging lever „K 2“

q	is removed and installed together with lower part of guide sleeve

7 -	Small engaging lever for „K 2“

q	is removed and installed together with upper and lower part of guide sleeve

8 -

Ball stud

q	Small small engaging lever „K 2“

q	→ Chapter „Adjusting position of clutch engagement bearings K 1 and K 2“

9 -

Bolts

q

8Nm + 90°

q	Always renew

10 -	Lower part of guide sleeve

q	Small small engaging lever „K 2“

q	is removed and installed together with upper part of guide sleeve

Special tools and workshop equipment required t  Depth gauge, digital 300 mm -VAS 6594-

t  Gauge block -T10466-

t  Ruler -T40100- Requirement: l  The gearbox flange must be level to assure good contact with the ruler. l  Mechatronic unit for dual clutch gearbox -J743- must be removed.   Caution Risk of damage to clutch and other components! Mounting for engaging lever and entire mechanism of engagement bearing must be dry and free of oil or grease.

–  Remove installed ball stud using pliers.

–  Push in »new« ball stud by hand, if necessary using a plastic hammer and drift to tap it in.   Note To avoid damage to ball stud, only tap the drift lightly with the hammer.

–  Install old retaining ring of outer input shaft.

1. step: Determine dimension „B“ for clutch „K 1“ and „K 2“

–  Place ruler -T40100- upwards across end of shaft onto gearbox flange.   Caution Risk of false measurements. The ruler -T40100- should remain in this position for the following measurements. Do not turn over, do not remove.

–  Place digital 300 mm depth gauge -VAS 6594- on top of ruler -T40100- and position depth gauge rod on outer input shaft. –  Set depth gauge to „0“.

–  Position depth gauge rod on retaining ring, as show in diagram. –  In this position, determine dimension „B1“ to retaining ring. l  Example: dimension „B1“ = 2.62 mm

–  In the opposite position, determine dimension „B2“ to retaining ring.   Note Do not measure on retaining ring joint. The retaining ring could be pushed away and falsify the reading. l  Example: dimension „B2“ = 2.58 mm –  Calculate mean value from dimension „B1“ and „B2“.    Formula: B1 + B2 2 Example: l  2,62 + 2,58 2 = 2.60 mm l  Result: Dimension „B“ = 2.60 mm   Note If the dual clutch was installed after this measurement, it must now be removed → Anchor.

–  Remove and dispose of outer input shaft.   WARNING It is not permissible to reuse the retaining ring.

2. step: Determine dimension „A1“ for clutch engaging lever „K 1“.

–  Insert large engaging lever.   WARNING Do not insert any shim! –  Check that engaging lever is seated correctly.

–  Place end gauge -T10466- on large engagement bearing. Flat side faces upwards. –  To ensure that end gauge -T10466- sits properly on engagement bearing, press down and turn end gauge. l  Engagement bearing will turn with end gauge -T10466-.

–  Place digital 300 mm depth gauge -VAS 6594- on top of ruler and position depth gauge rod on outer input shaft. l  Ruler -T40100- is lying upwards across end of shaft on gearbox flange.   Caution Risk of false measurements. The ruler -T40100- should remain in this position for the following measurements. Do not turn over, do not remove. –  Set depth gauge to „0“.

–  Position depth gauge rod on end gauge -T10466-, as show in diagram. –  In this position, determine dimension „A 1a“ to end gauge -T10466-. l  Example: Dimension „A 1a“ = 4.93 mm

–  In the opposite position, determine dimension „A 1b“ to end gauge -T10466-. l  Example: Dimension „A 1b“ = 4.91 mm –  Calculate mean value from dimension „A 1a“ and „A 1b“.    Formula: A 1a + A 1b 2 Example: l  4,93 + 4,91 2 = 4.92mm l  Result: Dimension „A 1“ = 4.92 mm 3. step: Calculate height tolerance of clutch engagement bearing „K 1“.   Note On the basis of dimension „A1“ and dimension „B“, the height tolerance of the clutch engagement bearing „K 1“ is now calculated according to the following calculus.

	Dimension „A 1“
–	Dimension „B“
=	Actual height tolerance of clutch engagement bearing „K 1“

Example: l  4.92 mm – 2.60 mm = 2.32 mm l  Result: Height tolerance of clutch engagement bearing „K 1“ = 2.32 mm

4. step: Calculate clutch tolerance „K 1“. –  Take clutch tolerance value from new clutch. l  Example: Read off clutch tolerance value on clutch „K 1 = +0.2“, as shown in diagram. 5. step: Determining thickness of shim „SK 1“-   Note On the basis of the clutch tolerance „K 1“, the thickness of shim „SK1“ is now calculated according to the following calculus.

	Height tolerance of engagement bearing „K 1“
–/+	Clutch tolerance of clutch „K 1“
=	Calculated thickness of shim „SK 1“

Example: l  2.32 mm + 0.20 mm = 2.52 mm l  Result: Calculated thickness of shim „SK 1“ = 2.52 mm

–  Select required shim from the table with the help of the part number -magnifying glass- and have it ready for installation.

Calculated thickness of shim mm	Available shims Thickness in mm	Part number of shim
1.21 … 1.60	1.50	0AM 141 383
1.61 … 1.80	1.70	0AM 141 383 A
1.81 … 2.00	1.00	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	2.00	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

Example: l  Result: Calculated thickness of shim „SK 1“ = 2.52 mm l  Chosen shim thickness = 2.50 mm = part number DAM 141 383 E   WARNING To avoid damage to clutch, only fit this shim later.

–  Remove end gauge -T10466- and large engagement lever again.

6. step: Determine dimension „A 2“ for clutch engaging lever „K 2“   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.

–  Install »small« engagement lever together with upper and lower parts of guide sleeve. Insert and tighten new bolts. Specified torque: → Anchor

–  Insert »small« engagement bearing without shim   WARNING Do not insert any shims!

l  Small engagement bearing only fits in one position due to 8 grooves. –  By turning, check whether small engagement bearing has been installed correctly and that grooves are seated correctly.

–  Place end gauge -T10466- on small engagement bearing. Flat side faces upwards. –  To ensure that end gauge -T10466- sits properly on engagement bearing, press down and turn end gauge. l  Engagement bearing will turn with end gauge -T10466-.

–  Place digital 300 mm depth gauge -VAS 6594- on top of ruler and position depth gauge rod on outer input shaft. l  Ruler -T40100- is lying upwards across end of shaft on gearbox flange.   Caution Risk of false measurements. The ruler -T40100- should remain in this position for the following measurements. Do not turn over, do not remove. –  Set depth gauge to „0“.

–  Position depth gauge rod on end gauge -T10466-, as show in diagram. –  In this position, determine dimension „A 2a“ to end gauge -T10466-. l  Example: Dimension „A 2a“ = 4.79 mm

–  In the opposite position, determine dimension „A 2b“ to end gauge -T10466-. l  Example: Dimension „A 2b“ = 4.75 mm –  Calculate mean value from dimension „A 2a“ and „A 2b“.    Formula: A 2a + A 2b 2 Example: l  4,79 + 4,75 2 = 4.77 mm l  Result: Dimension „A 2“ = 4.77 mm 7. step: Calculate height tolerance of clutch engagement bearing „K 2“.   Note On the basis of dimension „A 2“ and dimension „B“, the height tolerance of the clutch engagement bearing „K 2“ is now calculated according to the following calculus.

	Dimension „A 2“
–	Dimension „B“
=	Actual height tolerance of clutch engagement bearing „K 2“

Example: l  4.77 mm – 2.60 mm = 2.17 mm l  Result: Height tolerance of clutch engagement bearing „K 2“ = 2.17 mm

8. step: Calculate clutch tolerance „K 2“. –  Take clutch tolerance value from new clutch. l  Example: Read off clutch tolerance value on clutch „K 2 = – 0.2“, as shown in diagram. 9. step: Determining thickness of shim „SK 2“-   Note On the basis of the clutch tolerance „K 2“, the thickness of shim „SK 2“ is now calculated according to the following calculus.

	Height tolerance of engagement bearing „K 2“
–/+	Clutch tolerance of clutch „K 2“
=	Calculated thickness of shim „SK 2“

Example: l  2.17 mm – 0.20 mm = 1.97 mm l  Result: Calculated thickness of shim „SK 2“ = 1.97 mm

–  From the shims supplied, measure the required shim and have it ready for installation.

Calculated thickness of shim mm	Available shims Thickness in mm
0.31 … 0.00	0.80
0.01 … 1.10	1.00
1.11 … 1.30	1.20
1.31 … 1.50	1.40
1.51 … 1.70	1.60
1.71 … 1.00	1.80
1.01 … 2.10	2.00
2.11 … 2.30	2.20
2.31 … 2.50	2.40
2.51 … 2.70	2.60
2.71 … 3.30	2.80

Example: l  Result: Calculated thickness of shim „SK 2“ = 1.97 mm l  Chosen shim thickness = 2.00 mm   WARNING To avoid damage to clutch, only fit this shim later. The adjusting work has not been completed and the »small« engagement lever has already been installed. The next step now is to install the clutch again. –  Install clutch → Chapter.