Dual Clutch, Installing: Notes

Special tools and workshop equipment required

Clutch Retaining Bar: T10303
Dial Gauge Holder: VW387
Clutch Cover Plate Guide Sleeve: T10302

Procedure

Fig 1: Identifying Clutch From Wrapping, Removal

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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.

Fig 2: Identifying Drive Plate Secured In Outer Clutch Pack Carrier With Old Circlip From Removed Clutch

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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.

Fig 3: Identifying Ring Installation Position

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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.

Fig 4: Identifying Clutch Retaining Bar T10303 Position

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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-.

Fig 5: Placing Multi-Plate Clutch Into Clutch Bell Housing Using Rotational And Vertical Movements

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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.

Fig 6: Identifying Clutch Retaining Bar T10303

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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.

Fig 7: Clutch Cover Location

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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-.

Fig 8: Identifying Circlip Pried Out Using A Screwdriver

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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.

Fig 9: Identifying Clutch Cover And Clutch

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-- Move the drive plate to the side.