Volkswagen Workshop Service and Repair Manuals

Installing and adjusting the dual clutch   Caution t  The drive plate of a new clutch is not secured with a retaining ring. It is merely „firmly“ seated in the clutch. t  For that reason, press the drive plate into the outer plate carrier with both thumbs during the following steps. t  The drive plate has to remain engaged between the teeth of the outer plate carrier. t  If the drive plate is released, the plates in the dual clutch can shift. It may then not be possible to configure the clutch correctly when it is installed.

–  When removing dual clutch from its packaging, press drive plate into outer plate carrier with both thumbs.

–  Then secure drive plate in outer plate carrier using „old“ retaining ring -A- from removed clutch. l  Do not use the new retaining ring supplied. l  The retaining ring must be fitted such that the lug of the drive plate -arrow- and the colour-marked teeth of the outer plate carrier lie between the two ends of the retaining ring.

–  Check that 4 hub seals on underside of dual clutch are correctly seated. If necessary, ensure that seals engage with each other. l  The butt joints of the rings should be offset relative to each other, i.e. should not be positioned above each other. –  Turn rings once. They must move freely and must not bind.

Important! Installation location of the drive plate –  Please check whether projecting lug -arrow- of drive plate is positioned between colour-marked teeth of outer plate carrier. If there is no mark: –  Mark installation location of lug relative to periphery of outer plate carrier with permanent marker, as shown in illustration. l  During installation, the drive plate lug must always be repositioned at this marked location.

–  Place retaining pin -T10303- on seat of clutch end cover.

–  Locate dual clutch in clutch housing, rotating and raising/lowering it as you do so, but do not drop into position. During installation, press drive plate into outer plate carrier with both thumbs -arrows-.

l  The retaining pin -T10303- should be held by a second mechanic in the process.   Note t  The retaining pin remains inserted until the clutch end cover is installed. t  The dual clutch must then not be rotated any more as this can shift the position of the retaining pin -T10303-.

–  Lever out old retaining ring -2- using screwdriver -1--arrow- and dispose of it.   Caution Under no circumstances remove or raise the inner plate carrier. The plates could turn.

–  Remove drive plate from installed clutch -arrows-, levering carefully out of teeth of outer plate carrier with screwdriver if necessary. –  Lay drive plate aside.

Determining correct retaining ring for dual clutch –  Select 2 mm retaining ring from among rings supplied and install it -arrow-.   Note This retaining ring is used temporarily to measure the axial play. First measurement: l  Retaining pin -T10303- remains in! –  Screw universal dial gauge -VW 387- to gearbox flange.

–  Set -tip of dial gauge- on input shaft. –  Set -dial gauge- to 0 with preload. –  Raise clutch to stop and note result of measurement. Second measurement: l  Retaining pin -T10303- remains in!

–  Set tip of dial gauge -on hub of large plate carrier-. l  Tip must not sit on retaining ring. –  Set -dial gauge- to 0 with preload again. –  Raise clutch to stop again and also note this result. Now it can be determined which of the remaining 9 rings will ultimately be installed: –  Use this formula:    2nd reading – 1st reading + 1.85 mm = thickness of retaining ring to fit –  Please note down this result. The remaining 9 retaining rings are in increments of 0.1 millimetre. –  Measure all rings and determine which ring is closest to your result.

Determined size for new retaining ring	New retaining ring
2.27 mm	2.3 mm
2.24 mm	2.2 mm

–  Remove 2 mm thick ring and install calculated ring. –  Dispose of all remaining rings and the 2 mm ring.   Note Retaining rings are only allowed to be installed once.

–  Insert -pump shaft-.   Note Slightly raise and rotate the pump shaft in the process -arrow- so that it fully engages the gearing.

–  Fit drive plate in dual clutch. l  The projecting lug of the drive plate must be positioned between the colour-marked teeth of the outer plate carrier. Align subsequently applied markings.

–  Install »new« drive plate retaining ring. l  The retaining ring must be fitted such that the lug of the drive plate and the colour-marked teeth of the outer plate carrier lie between the two ends of the retaining ring. l  The retaining ring must be fully engaged. –  Use screwdriver to check that retaining ring is correctly seated and engaged. –  Then remove retaining pin -T10303- from between dual clutch and housing. –  Install clutch end cover → Chapter.