Dual Clutch, Adjusting (Determining Circlip Thickness)

Fig 1: Identifying Circlip Temporarily Installed

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 2: Identifying Dial Gauge Button And Input Shaft

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 3: Identifying Gauge Button Placed On Hub On Large Clutch Pack Carrier

Courtesy of AUDI OF AMERICA, LLC

• 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.

Fig 4: Identifying Circlip Temporarily Installed

Courtesy of AUDI OF AMERICA, LLC

• 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.

Fig 5: Inserting Pump Shaft

Courtesy of AUDI OF AMERICA, LLC

-- Insert the drive plate into the dual clutch.

Fig 6: Clutch Cover Location

Courtesy of AUDI OF AMERICA, LLC

• 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.

Fig 7: Inserting Clutch Cover So That Tab Aligns With Mark

Courtesy of AUDI OF AMERICA, LLC

• 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.

Fig 8: Clutch End Cover

Courtesy of AUDI OF AMERICA, LLC

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

Fig 9: Attention: Never Oil Center Seal Or Touch With Hand

Courtesy of AUDI OF AMERICA, LLC

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

Fig 10: Holding Clutch End Cover

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Clutch End Cover without Bushing: 

Fig 11: Identifying Cover Delivered Without Bushing

Courtesy of AUDI OF AMERICA, LLC

-- Place the : T10302  on a level surface.

Fig 12: Guiding Cover Horizontally And Evenly Over Entire Sleeve

Courtesy of AUDI OF AMERICA, LLC

-- To pre-form the inner seal on the new clutch end cover, guide the clutch end cover with the outer side facing downward evenly and horizontally over the : T10302  .

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

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

Fig 13: Cover Guided Horizontally Over Sleeve

Courtesy of AUDI OF AMERICA, LLC

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

-- If necessary, carefully pry the clutch end cover into its seat with a screwdriver -arrow- as shown until the shaft ring can be installed.

Fig 14: Identifying Cover In Its Seat Pried With A Screwdriver

Courtesy of AUDI OF AMERICA, LLC

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

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

-- Remove the : T10302  .

Clutch End Cover with Bushing (Assembly Aid): 

Fig 15: Caution - Do Not Remove Bushing!

Courtesy of AUDI OF AMERICA, LLC

-- Insert the clutch end cover with the bushing.

Fig 16: Identifying Cover With Bushing

Courtesy of AUDI OF AMERICA, LLC

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

-- If necessary, carefully pry the clutch end cover into its seat with a screwdriver -arrow- as shown until the shaft ring can be installed.

Fig 17: Identifying Cover In Its Seat Pried With A Screwdriver

Courtesy of AUDI OF AMERICA, LLC

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

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

-- Remove the bushing (assembly aid).

Fig 18: Identifying Cover With Bushing

Courtesy of AUDI OF AMERICA, LLC

Continuation for Both Clutch End Covers: 

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

-- Perform the basic setting using the Vehicle Diagnostic Tester in Guided Functions  .