Volkswagen Workshop Service and Repair Manuals

Installing dual clutch Special tools and workshop equipment required

t  Support device -T10323-

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

t  Puller -T10373-

t  Thrust piece -T10376- t  Adhesive -AMV 195 KD1 01- l  Torque settings → Chapter „Assembly overview - dual clutch“. Installing   Note If a further tightening angle is specified for certain bolts, these must be renewed.   Caution Risk of damage to clutch and other components! Clutch parts must be free of oil and grease.   Note The following four work steps are only necessary if the position of the engagement bearings did not have to be adjusted.

–  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.   Caution Risk of damage to clutch and other components! The positions of the engagement bearings must be set correctly. Adjustment can only be carried out before the clutch is installed. 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 were renewed. If any of the work above has been carried out, you must now adjust the position of engagement bearings „K 1 and K 2“ → Chapter. Do not continue with assembly until the setting is correct! If no new parts have been installed, use removed shims. For adjustment, only one shim per engagement bearing may be installed.

–  Insert small engagement bearings with measured shim for „K 2“. Shim should be under small engagement bearing. Therefore, insert shim first.

l  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.

–  Fix »large« shim for „K 1“ in place with 3 drops of adhesive -AMV 195 KD1 01-. This prevents shim from slipping out of its seat when clutch is inserted.

–  Turn back spindle of puller -T10373-.   Caution Risk of damage from clutch adjustment device. The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Do not allow clutch to fall into gearbox during installation. –  Install clutch with puller -T10373- in gearbox, as shown in diagram.

–  Position support bracket -T10323- parallel to gearbox flange as shown in illustration. –  If necessary, balance out gaps using -T10356/5- from assembly tool -T10356-, for example. –  Screw in bolts -A- hand-tight.   Note Bolts -A-, secure with nut as required. –  Press on clutch as far as it will go.   Note Place a hand on the clutch when pressing it on. A slight »rattling« will be felt. Rattling indicates that the clutch is being pressed onto its press seat. This also enables detection of the limit stop once the clutch has been seated correctly.

–  Take hold of new retaining ring with retaining ring pliers, as shown in the illustration. l  Installation position: narrow surface of retaining ring on top.

–  Inserting retaining ring -arrow-.   Note If the retaining ring cannot be inserted, the clutch has not been pressed in onto its limit stop.

–  To ensure that the clutch reaches its operating position right from this stage, turn it against puller -T10373--arrow- by hand without using any other tools.   Note t  By pressing on, the clutch sits at the bottom against the limit stop on the input shaft. This is not the optimum position.

t  Clutch should only be pulled up far enough for it to contact retaining ring.   Note Only turn by hand. In this way, clutch slides against retaining ring. Do not use any other tool.

–  Insert hub. l  Hub has »large tooth«-arrow- and only fits in one position. l  »Large tooth« has a mark at engine end.

–  Insert retaining ring -arrow- of hub. l  Joint of retaining ring must point towards »hub« of clutch.

–  Turn clutch by hand and observe small engaging lever whilst turning.

l  While the clutch is being turned, it must be ensured that the small engaging lever remains absolutely still. It must be ensured that it does not move up and down.   Note t  If an engaging lever moves up and down, the shim is not properly seated. t  In this case, remove clutch again → Chapter.

t  Check shims -arrows-. t  The shims must be properly seated and must not be damaged.

–  Remove two plugs and put breather caps -arrows-on. –  Dispose of excess shims. –  After installation of gearbox, perform Complete reset by means of Guided functions → Vehicle diagnostic tester.