Clutch Cap
Clutch Cap
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Transmission Support (VW 353)
• Guide Sleeve (T10302)
Removing
• Observe notes for Direct Shift Automatic Transmission 02E => [ Notes for Direct Shift Automatic Transmission 02E ] Notes For Direct Shift Automatic Transmission 02E.
• Observe general repair notes for working on the transmission => [ General Repair Notes ] General Repair Notes.
• 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 => [ Transmission, Removing ] Transmission, Removing.
- Attach transmission to assembly stand => [ Transmission, Attaching to Assembly Stand ] Transmission, Attaching 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.
• Always replace O-ring - 2 -.
- Remove filter - 3 -.
• 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 => [ Clutch, Installing and Adjusting ] Clutch, Installing and Adjusting
Installing
• 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.