Dual Clutch, Installing: Procedure

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CAUTION:

Risk of discs in double clutch slipping.

If the drive plate comes out of the outer clutch pack carrier teeth, the plates can slip. The double clutch can no longer be adjusted correctly.
To ensure multi-plate clutch discs do not slip, press drive plate into outer clutch pack carrier with thumbs during all of the following steps.

NOTE:

The drive plate circlip delivered in the replacement parts package will be installed later.

-- Remove the new drive plate circlip from packaging and lay it aside.

-- Remove the clutch from packaging while securing drive plate.

-- Install the old drive plate locking ring -A- in the double clutch removed earlier.

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Installed position: Drive plate tab and outer clutch pack carrier teeth marked in color must lie between ends of circlip.

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

-- On the bottom side of double clutch, check whether hub sealing rings are seated correctly and engage them in one another if necessary.

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Installed position: the ends of the ring are offset to each other.

-- Position the :T10303 on the clutch end plate seat as illustrated.

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-- Insert the clutch in clutch bell housing by turning and lifting and pressing drive plate into outer clutch pack carrier with both thumbs in direction of -arrows-.

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NOTE:

Do not let the clutch fall into the inner clutch pack carrier.

-- Have a second technician hold the :T10303 as illustrated until clutch end plate is installed.

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NOTE:

To prevent the :T10303 from rotating in place, do not rotate multi-plate clutch.

-- Verify that the protruding tab -arrow- of the drive plate is positioned between the color-marked teeth of the outer clutch pack carrier.

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-- If there is no marking, mark the location of the drive plate to outer clutch pack carrier circumference for reinstallation with a waterproof marker as shown in the illustration.

NOTE:

When installing, drive plate tab must be placed back on this marked location.

-- Remove the old locking ring -2- with a screwdriver -1- in direction of -arrow-.

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CAUTION:

Risk of discs in double clutch slipping.

If the inner clutch pack carrier is removed or raised, discs can slip. The double clutch can no longer be adjusted correctly.

-- Remove the drive plate in direction of -arrows-. If necessary, carefully pry the drive plate out of outer clutch pack carrier teeth using a screwdriver.

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-- Move the drive plate to the side.

Clutch, adjusting (determine circlip thickness)

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-- Find the 2 mm thick circlips in the replacement parts package.

NOTE:

For the initial measurement, temporarily insert 2 mm thick circlip and then, after the measurement has been determined, replace it with the final circlip.

-- Insert a 2 mm locking ring -arrow-.

-- Attach the :VW387 to the transmission flange.

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-- For the 1st measurement, place dial gauge measuring tip on input shaft, as show in the illustration.

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

-- Raise the double clutch all the way up.

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

-- For the 2nd measurement, place dial gauge measuring tip on inner clutch pack carrier hub, as show in the illustration.

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NOTE:

Measuring tip must not be placed on circlip.

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

-- Raise the double clutch all the way up.

-- Read the measurement and note.

The new circlip will be 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 0.05 on is rounded up.

Example:

Measurement determined for new circlip 2.27 mm, new circlip rounded up to 2.3 mm thick.
Measurement determined for new circlip 2.24 mm, new circlip rounded down to 2.2 mm thick.

NOTE:

If the measurement determined for the new circlip is 2 mm, the circlip that was inserted temporarily remains installed.

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

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NOTE:

The circlips may be used only one time.

Dispose of the removed circlip that was inserted temporarily as well as the remaining circlips.

-- Insert pump shaft by raising shaft and turning slightly -arrow- so it engages completely in splines.

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-- Insert the drive plate into the clutch.

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The protruding tab on the drive plate -arrow- must be installed between the marked teeth or the marking applied to the outer clutch pack carrier.

-- Install the new drive plate circlip.

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Installed position: The drive plate tab and marked teeth or outer clutch pack carrier marking that was applied must lie between the ends of the circlip.

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

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

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CAUTION:

Risk of leaking at clutch end cover contact surface.

Lubricate clutch end cover inner seal contact surface on drive plate -arrow-.

-- Clean clutch end cover outer seal contact surface.

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CAUTION:

Risk of leaking at clutch end cover inner seal.

To ensure the inner seal remains absolutely free of oil, do not touch seal with hands.

-- Remove the clutch end cover from the replacement parts package, only touching cover on outer edge.

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-- Clean the end of transmission shaft.

NOTE:

Only the clutch end cover outer seal may be coated with gear oil.

If there are stickers on the outside or inside of the clutch end cover, they must be removed without leaving any residue.

Clutch End Cover without Bushing

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-- Place the :T10302 on a level surface.

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-- To form the inner seal to the new clutch end cover, guide clutch end cover with outer side down evenly and horizontally over the :T10302 .

-- Remove the :T10302 upward out of the clutch end cover.

-- Place the :T10302 on the end of the clutch shaft.

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CAUTION:

Risk of damaging clutch end cover.

Do not drive clutch end cover on with hammer.

-- Guide the clutch end cover with outer side up horizontally over the :T10302 and press it evenly into the seat.

-- If necessary, carefully pry clutch end cover into seat with a screwdriver -arrow-, as illustrated until it is possible to install the shaft ring.

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-- Install clutch end cover shaft ring in transmission housing by counterholding shaft ring on the opposite side so it remains in its groove.

-- Using a screwdriver, make sure the shaft ring is completely engaged.

-- Remove the :T10302 .

Clutch End Cove with Bushing (Assembly Aid):

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-- Insert the clutch end cover and socket.

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CAUTION:

Risk of damaging clutch end cover.

Do not drive clutch end cover on with hammer.

-- Push the clutch end cover evenly into the seat.

-- If necessary, carefully pry clutch end cover into seat with a screwdriver -arrow-, as illustrated until it is possible to install the shaft ring.

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-- Install clutch end cover shaft ring in transmission housing by counterholding shaft ring on the opposite side so it remains in its groove.

-- Using a screwdriver, make sure the shaft ring is completely engaged.

-- Remove the bushing (assembly aid):

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Procedure for Both Clutch End Covers:

-- Fill the transmission fluid for the S tronic transmission after installing it. Refer to TRANSMISSION FLUID, DRAINING AND FILLING .

-- Perform basic setting. Refer to Vehicle Diagnostic Tester, Guided Functions .