Cap (Sealing Cap) For Clutch, Removing and Installing

Cap (Sealing Cap) For Clutch, Removing and Installing, 02E, 6 SPD. DSG A/T

Special tools, testers and auxiliary items required





Holding Plate VW 309





Transmission Support VW 353





Guide Sleeve T10302

Removing

Note:
Observe notes for Direct Shift Automatic Transmission.
Observe general repair notes for working on the transmission.
The cap is held in place by a securing ring. After securing ring has been removed, cap can be pried out of seating.
Cap and securing ring must always be replaced.





Never install a new cap using a hammer and never oil the center seal or touch with the hand! Leaks would result from this.

To work on the cap, transmission must be removed.

- Remove transmission.
- Attach transmission to assembly stand.

CAUTION!
Wear protective glasses.
Wear protective gloves.





- Remove bolt - A - near pendulum support.

Up to transmission production date "September 20, 2004" , transmissions with two bolts were installed.

A plastic overflow tube is located in this hole (with 8 mm hex socket head, torque specification: 3 Nm). Its length determines the oil level in the transmission.

- Remove oil tube.
- Drain oil.
- Hand-tighten overflow tube to 3 Nm.





- Replace seal - arrow -.
- Install bolt - arrow - and tighten to 45 Nm.





- Remove filter housing - 1 - from transmission.
- Before removing filter housing from transmission, tip it slightly in its seating.

This allows oil to flow back into transmission from filter housing.

Note:
Always replace O-ring - 2 -.

- Remove filter - 3 -.


Note:
An O-ring is located in suction collar of filter. Make sure that it does not remain hanging in the transmission, remove old O-ring if necessary.

- Coat new O-ring - 2 - with transmission oil.





- Coat O-ring in suction collar - arrow - of new filter with transmission oil.
- Insert new filter with suction collar - arrow - downward and tighten filter housing to 20 Nm.
- After performing repairs, the filter does not need to be changed again when filling with oil.
- Remove securing ring from cap.

Cap can be pried out using a screwdriver.

Only install new cap.

Installing

Note:
Cap and securing ring must always be replaced.





Never install a new cap using a hammer and never oil the center seal or touch with the hand!

CAUTION!
Do not grasp a new cap in the center hole. Cap must not be touched, oiled or come into contact with other substances there. Leaks would result from this.





- Grasp cap - A - in the hand only as shown in the illustration!
- Clean Guide Sleeve T10302 before use, do not use scratched assembly sleeves.

New cap in area of center seal must be free of oil and dry!

- If required, clean shaft end of clutch cap for transmission.

Only outer edge of seal may be coated with transmission oil for direct shaft transmission 02E.

- Place Guide Sleeve T10302 on a level surface.





Center seal - B - of new cap - A - must now be pre-shaped:

- Guide it horizontally and evenly over entire Guide Sleeve T10302 . This sets the sealing lips in installation position.
- Now remove Guide Sleeve T10302 upward from cap and place Guide Sleeve on shaft end of clutch cap for transmission.





- Guide cap - A - horizontally over Guide Sleeve T10302 and press into place uniformly.

CAUTION!
Handle with care. Any kind of blow - even very light ones - on the cap will certainly lead to leaks.





It is possible to pry the cap into its place - arrow - carefully using a screwdriver - 1 -, until new securing ring can be installed.

- Install new securing ring.