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Removing and installing the dual clutch > < Capacity

Golf Mk5

Assembly overview - dual clutch
Assembly overview - dual clutch
Brief description
t  The dual clutch has 2 sets of plates. The outer, larger set of plates is called „C 1“ (clutch 1). The „C 1“ selects reverse gear and gears »1«, »3« and »5«. The smaller inner „C 2“ (clutch 2) selects gears »2«, »4« and »6«.
t  The assembly of the dual clutch requires special care because all components were balanced together during manufacture. If parts are rotated relative to each other during assembly, imbalances develop which are detrimental to ease of shifting and service life.
   
Spare parts
1 - Dual clutch with retaining ring
  Caution
t  The drive plate (upper part of the dual clutch) of a new clutch is not secured with the retaining ring. It is merely »firmly« seated in the clutch.
t  The drive plate has to remain engaged between the teeth of the outer plate carrier.
t  If the drive plate is released, the discs in the dual clutch can shift, as a result of which the clutch may not be correctly configured when it is installed.
2 - Retaining ring
q   Qty. 10, of varying thickness as appropriate
q   The thickness of the retaining ring has to be determined when installing the clutch → Anchor
3 - Clutch end cover
4 - Retaining ring for clutch end cover

   
Individual parts of the disassembled dual clutch
  Caution
t  This figure is only intended to provide an overview of the components. The dual clutch must not be disassembled at present since all the plates have been balanced relative to each other.
t  If the drive plate is released, the discs in the dual clutch can shift, as a result of which the clutch may not be correctly configured when it is installed.
1 - Dual clutch/clutch housing
q   Outer plate carrier
2 - Oil seals
q   Qty. 4
3 - Inner plate carrier
q   Do not remove
  Caution
Under no circumstances raise or remove the inner plate carrier. The plates could turn.
4 - Outer plates
q   Qty. 4
5 - Inner plates
q   Qty. 4
6 - Thrust washer
7 - Retaining ring
q   If retaining ring was removed to insert new plates, it should be renewed with a new, equally thick ring
8 - Retaining ring
q   Determine thickness afresh if a new clutch has been fitted → Anchor
9 - Drive plate
10 - Retaining ring
q   Renew

   

Removing and installing the dual clutch > < Capacity