Skoda Workshop Service and Repair Manuals

Install the double clutch „new design“ as of 06.11 Special tools and workshop equipment required t  Extractor -T10373- t  Supporting bridge -T10323- t  Thrust piece -T10368- t  Thrust piece -T10376-   Note The large adjusting washer for the clutch „K1“ is inserted with the semispherical side downwards on the large bearing, the small adjusting washer for the clutch „K2“ is inserted under the small bearing. Before installing the clutch, the position of the engaging bearings „K 1 and K 2“ must be adjusted → Chapter. The position of the engaging lever must be adjusted if: t  The clutch was replaced t  The engaging levers were replaced t  The ball stud for „K2“ was replaced t  The engaging bearing was replaced. If all the mentioned parts are only removed and reinstalled, there is nothing to adjust. Do not oil or grease!

–  Insert hinge bearing -1- and ball stud -2-.

–  Insert the small engaging lever with the top and bottom part of the guide bushing. Tighten screws to tightening torque → Chapter.   Note The support of the engaging levers and the complete mechanism for the engaging bearings must be dry and free of oil or grease. If necessary, clean these component parts with a clean cloth.

–  Insert the second, »larger« engaging lever with the measured adjusting washers for clutch „K1“ and „K2“.   Note The large adjusting washer for the clutch „K1“ is inserted with the semispherical side downwards on the large bearing, the small adjusting washer for the clutch „K2“ is inserted under the small bearing.   Caution The small engaging bearing and the adjusting washer fit in only one position due to the 8 grooves.

–  Insert the »small« engaging bearing. –  While »turning« the bearing, check if it is correctly installed and the grooves are correctly positioned. –  Check the correct fit of both engaging levers. The large adjusting washer is used for the clutch „K1“, the small one is used for the clutch „K2“.

–  Insert the clutch. –  Insert the clutch into the gearbox using the extractor -T10373-. –  »Turn back« the spindle beforehand.   Note The clutch is self-adjusting. Vibrations can have an effect on this adjusting device. Therefore do not let the clutch fall. Do not let the clutch fall into the gearbox when installing it.

–  Position the supporting bridge -T10323- parallel to the flange of the clutch housing. –  Equalise distances, e.g using washers -B- with a total thickness of 15 mm. –  Attach the supporting bridge -T10323- with screws -A-.   Note Fasten screws -A- with nuts. –  Press the clutch downwards via the spindle.   Note t  Place one hand on the clutch when pressing on. A slight rattling can be felt. Rattling means that the clutch is pressed onto its press seat. »The stop must be felt« in this way when the clutch has reached its seat. t  The clutch is pressed in up to the stop if the circlip can be inserted.

Fitting position of the circlip: the joint of the circlip is »smaller at the top«.

–  Insert the new circlip -arrow-.   Note If the circlip cannot be inserted -arrow-, the clutch is not correctly pressed on up to the stop.

–  Turn the clutch against the extractor by hand so that the clutch reaches its operating position. l  Only turn the clutch by hand, do not use any tool.

Only turn by hand. In this way, the clutch slips against the circlip. Do not use any further tool. By pressing on the »clutch it is positioned at the bottom« on the drive shaft. The clutch should only be pulled up as far as necessary until it touches the circlip.

Subsequently insert the hub: The hub has a »large« tooth and therefore only fits in one position. On the -engine side-, the »large« tooth has a marking -arrow-.

–  Install the hub with the marking on the »large tooth« in such a way that it is flush with the marking on the drive plate -arrow-.

–  Insert the circlip for the hub -arrow-. Fitting location: The joint of the ring must point to the »lug« on the clutch.

–  Turn the clutch by hand and while turning it pay attention to the »small« engaging lever.

While doing so, the engaging lever »in standstill« must remain in its position. It must neither move up nor down. If the engaging lever moves up and down, the adjusting washers are not in their correct position.

–  In this case, remove the clutch again → Chapter. –  Have a close look at the adjusting washers -arrows-. l  The washers must be correctly positioned. They should not be damaged.

–  Remove the screw plugs and position both ventilation caps -arrows- again. Perform the basic setting after the gearbox has been fitted with the → Vehicle diagnostic tester.