Dual Clutch, Adjusting (Determining CIRCLIP Thickness)

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-- Find the circlips with a 2 mm thickness in the replacement part package.

• For the initial measurement, temporarily insert the 2 mm circlip and then, after the measured value has been calculated, replace it with the final circlip.

-- Insert a 2 mm circlip -arrow-.

-- Attach the :VW387  to the transmission flange.

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-- For the first measurement, place the dial gauge measuring tip onto the input shaft as shown.

-- Set the dial gauge to "0" with 2 mm pretension.

-- Raise the dual clutch all the way upward.

-- Read and note the measurement result (= input shaft axial play).

-- For the second measurement, place the dial gauge measuring tip on the inner clutch plate carrier hub as shown.

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• The measuring tip must not be placed on the circlip.

-- Set the dial gauge to "0" with 2 mm pretension.

-- Raise the dual clutch all the way upward.

-- Read and note the measurement result.

The new circlip is determined according to the following formula:

Circlip = 2. Measurement - 1. Measurement + 1.85 (= constant value)

The new circlips are staggered in 0.1 mm increments. Round to the closest number when selecting: up to 0.049 is rounded down, and from 0.050 is rounded up.

Example: 

• Determined dimension for new circlip: 2.27 mm; new circlip rounded up to 2.3 mm thick.
• Determined dimension for new circlip: 2.24 mm; new circlip rounded down to 2.2 mm thick.
• If the determined dimension for the new circlip is 2 mm, the circlip that was temporarily inserted remains installed.

-- Remove the 2 mm thick circlip that was temporarily inserted for measurement and replace with the circlip of the determined thickness.

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• The circlips may be used only one time.
• Dispose of the removed circlip that was inserted temporarily as well as the remaining circlips.

-- Insert the pump shaft by lifting the pump shaft and turning it slightly -arrow- so that it slides all the way into the splines.

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-- Insert the drive plate into the dual clutch.

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• The drive plate protruding tab -arrow- must be installed between the color-marked teeth or the markings that were applied later to the outer clutch plate carrier.

-- Install the drive plate circlip.

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• Installation position: the drive plate tab and the color-marked teeth or the markings that were applied later to the outer clutch plate carrier must lie between the ends of the circlip.

-- Using a screwdriver, check to make sure the circlip is completely engaged.

-- Remove the :T10303  between the dual clutch and the housing.

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-- Clean the contact surface for the outer clutch end cover seal.

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-- Remove the clutch end cover from the replacement part package. Only grab the clutch end cover at the outer edge.

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-- Clean the end of the transmission shaft.

• Only the outer clutch end cover seal may be coated with transmission fluid.
• If there are stickers on the outside or inside of the clutch end cover, they must be removed without leaving any residue.