SEAT 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 in the following cases: t  Clutch has been renewed. t  Engaging levers were renewed. t  Small ball stud for engaging lever „K 2“ has been renewed. t  Engagement bearings were 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. With this 7-speed dual clutch gearbox 0AM, there are tolerances in the pressing system of the gearbox and gear as well. There are also tolerances in dual clutches. 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 -

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 section of bushing

q	Small small engaging lever „K 2“

q	Is removed and installed together with lower section of bushing

7 -	Small engaging lever for „K 2“

q	Is removed and installed together with upper and lower section of bushing

8 -	Ball head 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 replace.

10 -	Lower section of bushing

q	Small small engaging lever „K 2“

q	Is removed and installed together with upper section of bushing

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter. Special tools and workshop equipment required t  Depth gauge, digital 300 mm -VAS 6594-

t  Gauge block -T10466-

t  Ruler -T40100- Prerequisites: 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 the clutch and other components! Mounting for engaging lever and entire mechanism of the 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 Tap on the mandrel lightly using a hammer. Otherwise the ball stud may be impaired.

–  Install old retaining ring of outer input shaft.

First 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 is still in place 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.

Second 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 Third step: determine the height tolerance of clutch engagement bearing „K 1“.   Note On the basis of dimension „A 1“ 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 the clutch engagement bearing „K 1“ = 2.32 mm

Forth step: determine the tolerance of clutch „K 1“ –  Take clutch tolerance value from new clutch. l  Example: read the tolerance value on clutch „K 1 = 0.2“, as shown in diagram. Fifth step: determine the shim „S K1“ thickness   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: determined 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	1,90	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	2,90	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: determined thickness of shim „SK 1“ = 2.52 mm l  Chosen shim thickness = 2.50 mm = part number 0AM 141 383 E   WARNING To avoid damage to clutch, only fit this shim later.

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

Sixth step: determine dimension „A2“ for clutch engaging lever „K 2“.   Note The upper section of bushing cannot be removed or installed alone. It is always removed or installed together with lower section of bushing and »small« engagement lever.

–  Install »small« engagement lever together with upper and lower section of bushing. Insert and tighten new bolts. Tightening torque → Anchor

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

l  The small engagement bearing only fits in one position due to the 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 Seventh step: determine the 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 the clutch engagement bearing „K 2“ = 2.17 mm

Eighth step: determine the tolerance of clutch „K 2“ –  Take clutch tolerance value from new clutch. l  Example: read the tolerance value on clutch „K 2 = - 0.2“, as shown in diagram. Ninth step: determine the shim „S K2“ thickness   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: determined 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 … 0,90	0,80
0,91 … 1,10	1,00
1,11 … 1,30	1,20
1,31 … 1,50	1,40
1,51 … 1,70	1,60
1,71 … 1,90	1,80
1,91 … 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: determined 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 now been completed and the »small« engagement lever has already been installed. The next step now is to install the clutch again. –  Install clutch → Chapter.