Clutch, Installing and Adjusting
Clutch, Installing and Adjusting
CAUTION!
Prevent the removal or lifting of the clutch carrier Not even slightly! The clutch discs can rotate themselves.
• Transmission must be rotated vertically in assembly stand and opening for clutch must face upward. Only in this way is it later also possible to adjust the clutch axial play.
• Transmission must always be clamped tightly in assembly stand => [ Transmission, Attaching to Assembly Stand ] Transmission, Attaching to Assembly Stand. It must not be rotated.
• In the clutch, the large clutch discs carrier installs all clutch discs, it must not be slipped out of lowest clutch disc.
• Input shaft of transmission oil pump has been removed.
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Transmission Support (VW 353)
• Dial Gauge Holder (VW 387)
• Retaining Bar (T10303)
• Dial gauge
- First, place Retaining Bar (T10303) on to seat - arrow - of cap (sealing cap).
- Then, carefully insert clutch direction of - arrow -, do not let it fall in.
Retaining Bar (T10303) must be held in place by a second technician when doing this.
Retaining Bar (T10303) remains there until clutch cap has been installed.
- Determine the ring with 2 mm thickness - arrow - from all supplied securing rings and install it temporarily.
Before this ring is removed again, two measurements must be performed first.
First measurement:
• Retaining Bar (T10303) remains installed!
- Install Dial Gauge Holder (VW 387) on to transmission flange.
- Place plunger of dial gauge on to transmission input shaft.
- Set dial gauge to "0" with pre-load.
- Lift clutch upward until it stops and note measurement result.
Second measurement:
• Retaining Bar (T10303) remains installed!
- Place plunger of dial gauge on to hub of large clutch discs carrier for clutch.
• Plunger must not rest on the securing ring.
- Reset dial gauge to "0" with pre-load.
- Lift clutch upward again until it stops and note this result as well.
Now it will be calculated which of the nine remaining securing rings will be installed finally:
- For this, use this formula:
Second measurement minus first measurement plus 1.85 mm = thickness of ring to be installed.
- Note this result.
The nine remaining securing rings are stepped in 0.1 mm increments.
- Measure all rings and then determine the ring which matches your result.
- Remove 2 millimeter thick ring and replace with determined ring.
- Insert input shaft for transmission oil pump, when doing this rotate slightly in direction of - arrow -.
- Insert clutch cap so that tab - arrow B - coincides with marking - arrow A -.
- Place new securing ring - 1 - into clutch.
- Remove Retaining Bar (T10303).
- Install cap (sealing cap) for clutch => [ Clutch, Installing and Adjusting ] Clutch, Installing and Adjusting.
This concludes the installation, the clutch is correctly adjusted.
After installing transmission:
- Basic calibration of Direct Shift Gearbox (DSG) Mechatronic (J743) is performed using Vehicle Diagnosis, Testing and Information System (VAS 5051) or Vehicle Diagnosis & Service Syst. (VAS 5052) in " Guided Fault Finding".