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  Retainer of engaging levers has been renewed. t  Engagement bearings have been renewed.   Note There is no need to adjust anything if all the named parts have only been removed and reinstalled. 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 -	Small engaging lever for »K 2«

2 -	Shim for »K 2«

3 -	Engagement bearings for »K 2«

4 -	Large engaging lever for „K 1“

q	With large engagement bearing

5 -	Shim for „K 1“

6 -

Bolts

q

8Nm + 90°

q	Always renew

7 -

Clip

q	No present in some older gearboxes

8 -

Support

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

t  Gauge block -T10374-

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. l  Torque settings → Chapter „Assembly overview - dual clutch“.   Note If a further tightening angle is specified for certain bolts, these must be renewed.   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.

1. step: Prepare dual clutch for measurement –  Insert retainer for engaging lever.

–  Install small engaging lever with clip.   Note Only a few, »older« gearboxes do not have a clip.

–  Bolt on engaging lever with 2 new bolts. Torque setting → Anchor

–  Insert large engaging lever. –  Check both engaging levers are seated correctly.

–  Install old retaining ring of outer input shaft.

2. 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“ = 2.92 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“ = 3.00 mm –  Calculate mean value from dimension „B1“ and „B2“.    Formula: B1 + B2 2 Example: l  2,92 + 3,00 2 = 2.96 mm l  Result: Dimension „B“ = 2.96 mm –  Remove and dispose of retaining ring.

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

–  Place end gauge -T10374- on large engagement bearing with large opening upwards. –  To ensure that end gauge -T10374- sits properly on engagement bearing, press down and turn end gauge. l  Engagement bearing will turn with end gauge -T10374-.

–  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 -T10374-, as show in diagram. –  In this position, determine dimension „A 1a“ to end gauge -T10374-. l  Example: Dimension „A 1a“ = 2.61 mm

–  In the opposite position, determine dimension „A 1b“ to end gauge -T10374-. l  Example: Dimension „A 1b“ = 2.81 mm –  Calculate mean value from dimension „A 1a“ and „A 1b“.    Formula: A 1a + A1b 2 Example: l  2,61 + 2,81 2 = 2.71 mm l  Result: Dimension „A 1“ = 2.71 mm 4. step: Calculate installation depth of clutch engagement bearing „K 1“   Note Using dimension „A1“ and dimension „B“, the actual installation depth of the clutch engagement bearing „K 1“ is now calculated based on the following calculus.

	Dimension „A 1“
–	Dimension „B“
+	Exterior height end gauge -T10374- (51.81 mm; fixed value)
=	Actual installation depth of clutch engagement bearing „K 1“

Example: l  2.71 mm – 2.96 mm + 51.81 mm = 51.56 mm l  Result: Installation depth of clutch engagement bearing „K 1“ = 51.56 mm 5. step: Calculate clearance of clutch „K 1“   Note With the actual value and specification for the engagement bearing installation depth, the clearance of clutch „K 1“ is now determined using the following calculus.

	Actual value of engagement bearing installation depth
–	Specification of engagement bearing installation depth (50.08 mm; fixed value)
=	Clearance of clutch „K 1“

Example: l  51.56 mm – 50.08 mm = 1.48 mm l  Result: Clearance of clutch „K 1“ = 1.48 mm

6. 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. 7. step: Determining shim „S K1“ thickness   Note On the basis of the clearance value and clutch tolerance „K 1“, the thickness of shim „SK 1“ is now calculated using the following calculus.

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

Example: l  1.48 mm + 0.20 mm = 1.68 mm l  Result: Calculated thickness of shim „SK 1“ = 1.68 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 1“ = 1.68 mm l  Chosen shim thickness = 1.60 mm =   Caution Risk of damage to gearbox t  Mark shim „SK 1“ and have it ready for assembly. t  For adjustment, only this shim „SK 1“ may be inserted for the small engaging lever.

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

–  Only insert small engagement bearing.

Small engagement bearing only fits in one position due to 4 grooves.

–  By turning -arrows-, check whether small engagement bearing is properly installed and that grooves are seated correctly.

–  Place end gauge -T10374- on small engagement bearing with large opening upwards.

–  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 -T10374-, as show in diagram. –  In this position, determine dimension „A 2a“ to end gauge -T10374-. l  Example: Dimension „A 2a“ = 2.50 mm

–  In the opposite position, determine dimension „A 2b“ to end gauge -T10374-. l  Example: Dimension „A 2b“ = 2.54 mm –  Calculate mean value from dimension „A 2a“ and „A 2b“.    Formula: A 2a + A 2b 2 Example: l  2,50 + 2,54 2 = 2.52 mm l  Result: Dimension „A 2“ = 2.52 mm 9. step: Calculate installation depth of clutch engagement bearing „K 2“   Note On the basis of dimension „A 2“ and dimension „B“, the actual installation depth of the clutch engagement bearing „K 2“ is now calculated based on the following calculus.

	Dimension „A 2“
–	Dimension „B“
+	Interior height end gauge -T10374- (36.20 mm; fixed value)
=	Actual installation depth of clutch engagement bearing „K 2“

Example: l  2.52 mm – 2.96 mm + 36.20 mm = 35.76 mm l  Result: Installation depth of clutch engagement bearing „K 2“ = 35.76 mm 10. step: Calculate clearance of clutch „K 2“   Note With the actual value and specification for the engagement bearing installation depth, the clearance of clutch „K 2“ is now determined using the following calculus.

	Actual value of engagement bearing installation depth
–	Specification of engagement bearing installation depth (34.35 mm; fixed value)
=	Clearance of clutch „K 2“

Example: l  35.76 mm – 34.35 mm = 1.41 mm l  Result: Clearance of clutch „K 2“ = 1.41 mm

11. 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. 12. step: Determining shim „SK 2“ thickness:   Note On the basis of the clearance value and clutch tolerance „K 2“, the thickness of shim „SK 2“ is now calculated using the following calculus.

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

Example: l  1.41 mm – 0.20 mm = 1.21 mm l  Result: Calculated thickness of shim „SK 2“ = 1.21 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“ = 1.21 mm l  Chosen shim thickness = 1.20 mm   Caution Risk of damage to gearbox t  Mark shim „SK 2“ and have it ready for assembly. t  For adjustment, only this shim „SK 2“ may be inserted. –  Install clutch → Chapter.