Section B - Dual Clutch Removal and Installation
- Remove caps from breather openings on the direct shift transmission -A- and bevel box
- Seal off breather opening -1- on direct shift transmission using suitable plug
- Seal off breather opening -2- on the bevel box using suitable plug
Securing Transmission to Assembly Stand in the Vertical Position
- Remove transmission from the 3282 holding tool on transmission jack and using bolts -1- and -2-, secure transmission to the VW353 transmission support
- Bolt the VW353 transmission support to the VW309 support plate
- Attach the transmission to the VW313 support clamp
NOTE:
To prevent damage, do not place the transmission down on the transmission oil pump cover.
Removing Clutch End Cover
- Using a screwdriver -A-, pry off circlip securing the clutch end cover
- Working through the starter opening, pry off the clutch end cover with a screwdriver -A- (alternatively pry off clutch end cover with a pry bar)
- Remove clutch end cover together with circlip
Removing the Dual Clutch
- Using a screwdriver, remove the circlip securing the drive plate
- Remove the drive plate
- Remove circlip on input shaft 1
- Lift up and remove the dual clutch
- After removing the dual clutch, check the clutch bell housing for damage caused during removal
- Remove pump shaft -A-
Installing the Dual Clutch
CAUTION:
- WHILE CARRYING OUT THE FOLLOWING STEPS, YOU MUST PRESS THE DRIVE PLATE INTO THE OUTER PLATE CARRIER WITH BOTH THUMBS.
- THE DRIVE PLATE MUST REMAIN ENGAGED BETWEEN THE SPLINES OF THE OUTER PLATE CARRIER.
- IF THE DRIVE PLATE COMES LOOSE, THE CLUTCH PLATES CAN SLIP OUT OF POSITION INSIDE THE DUAL CLUTCH UNIT. THIS COULD CAUSE INCORRECT ADJUSTMENT TO THE DUAL CLUTCH DURING INSTALLATION.
- Take the retaining ring out of the packaging
- Obtain new dual clutch (02E 141 029E) from repair kit; remove packaging while pressing the drive plate into the outer plate carrier with both thumbs
CAUTION:
DURING THE FOLLOWING STEPS, YOU MUST KEEP PRESSING THE DRIVE PLATE INTO THE OUTER PLATE CARRIER WITH BOTH THUMBS TO ENSURE THAT IT REMAINS IN POSITION BETWEEN THE SPLINES OF THE OUTER PLATE CARRIER.
- Check that the four oil seals -B- on the hub on the under side of the dual clutch are correctly seated; engage in position, if necessary
- While turning the new dual clutch in both directions, as well as moving it slightly up and down, lower it slightly onto the input shaft and at the same time insert the assembly tool -A- between the dual clutch and the bell housing. Turn it to a position at the edge of the housing so that it holds the dual clutch at a defined height.
NOTE:
The assembly tool is included in the repair kit
CAUTION:
DO NOT LET THE DUAL CLUTCH DROP DOWN WITHOUT HAVING THE ASSEMBLY TOOL IN PLACE.
WARNING:
Assembly tool must be in place during the entire time of set-up
- Correct position of tool -A- shows it in place on the step area -arrow- of the bell housing and holding the dual clutch at the correct height for doing measurements
NOTE:
The illustration shows tool -A- in position and the drive plate already removed. See next illustration for drive plate removal.
- The drive plate -A- is fitted in a specific position in relation to the outer plate carrier -B-
CAUTION:
- THE CORRECT POSITION FOR THE DRIVE PLATE TO BE INSTALLED IS WITH THE PROJECTING LUG ALIGNED BETWEEN THE COLOR-MARKED SPLINES ON THE OUTER PLATE CARRIER.
- IF PARTS ARE NOT COLOR-MARKED, USE A WATERPROOF PEN TO MARK THEM AT THIS TIME SO THEY CAN BE REASSEMBLED TO THE EXACT SAME POSITION. PARTS MUST BE MARKED BEFORE REMOVING THE DRIVE PLATE.
- If circlip is already installed and securing the drive plate, it needs to be removed; use a screwdriver to remove the circlip
NOTE:
Normally, new circlip comes as a new single part in the repair kit and is not already installed on the new dual clutch
- Lift out drive plate, if necessary, pry it carefully out of the splines on the outer plate carrier using a screwdriver
- Obtain circlip (02E 311 321H) from the repair kit with a thickness of "T(circlip)" = 2.0 mm and install onto flange
NOTE:
The circlip is temporarily installed for measuring the axial play
Preparations For Measuring Axial Play "E(W1)" of Transmission Input Shaft 1
- Set up the VW387 universal dial indicator bracket with dial indicator on the transmission flange
- Position tip of dial indicator vertically to transmission input shaft 1
- Lift clutch assembly up as far as it will go and read axial play "E(W1)" of transmission input shaft 1 indicated on the dial indicator
NOTE:
With a new transmission, it is possible to have 0 mm axial play "E(W1)"
Preparations for For Measuring Total Play "S(1)"
- Position tip of the dial indicator vertically to the hub of the inner plate carrier
NOTE:
The dial indicator point is positioned on the surface adjacent to the transmission input shaft 1
- Lift clutch assembly as far as it will go and read total play "S(1)" indicated on the dial indicator gauge
Calculating the Thickness of the New Circlip: "T (circlip new)"
Symbol Definition
"T(circlip new)" Thickness of new circlip
"S(1)" Total internal play (as measured)
"E(W1)" Axial play of input shaft 1 (as measured)
NOTE:
All dimensions are in millimeters
- Use the formula -> "T(circlip new)" = "S(1)" - "E(W1)" + 1.85 mm and calculate the thickness of the new circlip
Selecting the New Circlip of the Required Thickness: "T(circlip new)"
Circlip in repair kit
Part Number Thickness
02E 311 321 F 1.8 mm
02E 311 321 G 1.9 mm
02E 311 321 H 2.0 mm
02E 311 321 J 2.1 mm
02E 311 321 K 2.2 mm
02E 311 321 L 2.3 mm
02E 311 321 M 2.4 mm
02E 311 321 N 2.5 mm
02E 311 321 P 2.6 mm
02E 311 321 Q 2.7 mm
NOTE:
All the circlips (02E 311 321) are included in the repair kit. The thickness of the new circlips (02E 311 321) are graduated in steps of 0.1 mm. When selecting the required circlip, round off the dimension to the nearest 10th of a milli-meter (values up to 0.049 are rounded down and values of 0.05 and above are rounded up).
Examples:
Calculated value "T(circlip new)" = 2.27 mm = -> select circlip of thickness 2.3 mm
Calculated value "T(circlip new)" = 2.24 mm = -> select circlip of thickness 2.2 mm
- Remove the circlip of thickness "T(circlip new)"= 2.0 mm previously installed for making the initial measurements
NOTE:
If the calculated thickness of the new circlip is 2.0 mm, the previously installed circlip does not have to be removed
- Install new circlip with the required thickness previous calculated (always use a new circlip)
- Reinstall pump shaft -A-
IMPORTANT:
Lift the shaft and turn it slightly while installing to get it fully seated into the splines
NOTE: The dual clutch is already installed although the illustration does not show it in place
- Install drive plate onto the dual clutch making certain the lug on the drive plate is positioned opposite the color marked splines on the outer plate carrier and between the two ends of the circlip
CAUTION:
TO ENSURE THAT THE DRIVE PLATE IS INSTALLED IN THE CORRECT POSITION, OBSERVE THE COLORED MARKINGS IDENTIFYING THE POSITION OF THE DRIVE PLATE RELATIVE TO THE OUTER CARRIER
Requirements:
- The projecting lug on the drive plate must be positioned between the color marked splines on the outer plate carrier
- The circlip must be installed so that the lug on the drive plate and the color-marked splines on the outer plate carrier are located between the two ends of the circlip
- Install circlip securing the drive plate
CAUTION:
MAKE CERTAIN THE CIRCLIP IS FULLY SEATED
- Using a screwdriver, check that the circlip is properly seated and fully engaged
- Remove assembly tool -A- from between the dual clutch and the housing
- Pour 0.15 liter of transmission oil (G 052 182 A2) for direct shift transmission into clutch housing
Installing dual clutch end cover
- Thoroughly degrease the running surface of the seal using a cleaning solvent
CAUTION:
THE CONTACT SURFACES OF THE END COVER MUST BE CLEANED THOROUGHLY; OTHERWISE, LEAKS CAN OCCUR
- Clean the bell housing surface where the outer seal of the end cover will contact it
Preparing the End Cover
CAUTION:
- DO NOT TOUCH THE SEAL INSIDE THE OPENING IN THE END COVER. THIS SEAL WILL ONLY SEAL PROPERLY IF THE RUNNING SURFACE IS ABSOLUTELY FREE OF GREASE WHEN IT IS INSTALLED.
- DO NOT APPLY HAMMER BLOWS DIRECTLY TO THE END COVER. ANY FORCES APPLIED TO THE INSIDE RING WILL CAUSE MALFUNCTIONS.
- Remove packaging material from around the new end cover (02E 301 205 B) in the repair kit
NOTE:
Do not touch the seal inside the opening in the end cover
- Using the assembly tool from the repair kit, fit the clutch end cover on the tool
NOTE:
This will bring the seal inside the opening in the end cover into the correct position for installation
- The end cover must be in full contact with the assembly tool
- Lift off the tapered sleeve -2- from the assembly tool
- Insert the end cover with the assembly tool into the clutch bell housing, at the same time turning slightly
IMPORTANT: Make certain that the end cover is positioned uniformly in the clutch bell housing
- Tap the end cover into position with a plastic hammer
NOTE:
The end cover must be brought evenly into its final position. The slot for the circlip in the transmission bell housing should now be visible and accessible.
CAUTION:
DO NOT APPLY HAMMER BLOWS DIRECTLY TO THE PUMP COVER. THE END COVER CONSISTS OF TWO PARTS AND ANY FORCE APPLIED TO THE INSIDE RING WILL CAUSE MALFUNCTIONS
- Remove the assembly tool
- Install new circlip (02E 301 859 A) from the repair kit for the end cover
NOTE:
The circlip should be installed with opening up when the transmission is in vehicle position
- Check that the circlip is seated correctly, if necessary, press the outer ring of the cover down slightly using a metal bar or suitable tool to enable the circlip to fully engage
- Lubricate the splines -arrow- for the dual mass flywheel with a small quantity of assembly grease (G 000 100)
- Rotate the transmission support clamp, VW 313, to the normal position, e.g. with the breather openings facing upwards
- Carefully remove the transmission from the VW353 holding plate and place on the 3282 transmission support
- Proceed to Section C