Dual Clutch, Installing: Notes

Special tools and workshop equipment required 

• Clutch Cover Plate Guide Sleeve: T10302 
• Clutch Retaining Bar: T10303 
• Dial Gauge - 0-10mm: VAS6079 
• Dial Indicator Holder: VW387 

Brief Description 

• Adjust the clutch axial play when installing.
• Secure the transmission to the assembly stand so that it is vertical when removing and installing the clutch. This is the only position in which the clutch axial play can later be adjusted without malfunctions.
• The large clutch plate carrier is inserted in all clutch discs in the clutch. The large clutch plate carrier must not slide out of the lowest plate.
• Oil pump shaft is removed.
• Do not install any wavy circlips
• The drive plate (upper section of the dual clutch) of a new clutch is not secured with the circlip, it only sits "taut" in the clutch.
• The drive plate must remain engaged between the teeth of the outer clutch plate carrier.
• If the drive plate is loosened, the plates in the dual clutch can slip out of place and it cannot be adjusted correctly during installation under the circumstances.

Installing 

Fig 1: Identifying Clutch From Wrapping, Removal

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-- Use special caution when removing the dual clutch from the packaging.

• Do not remove or lift the clutch pack, not even a small amount. The clutch plates can rotate themselves.
• If the drive plate comes out of the outer clutch plate carrier teeth, the plates can slip. The dual clutch can then no longer be adjusted correctly.
• To ensure that the multiplate clutch plates do not slip, press the drive plate into the outer clutch plate carrier with both thumbs during all of the following steps.

-- Check on the bottom of the dual clutch if the four hub seals are seated correctly and engage them in one another if necessary.

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• Installation position: the ends of the rings are offset to each other.

Installation Position of the Drive Plate 

Fig 2: Clutch Cover Location

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• The protruding tab -arrow- must be positioned between the color-marked teeth of the outer clutch plate carrier.
• If no mark is present, the tab to the outer clutch plate carrier is marked all around with color.
• When installing, the drive plate tab must be placed back on this marked location.

-- Position the : T10303  on the clutch end cover seat as shown.

Fig 3: Identifying Clutch Retaining Bar T10303 Position

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-- Insert the dual 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 4: Placing Multi-Plate Clutch Into Clutch Bell Housing Using Rotational And Vertical Movements

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• Do not let the dual clutch fall into the inner clutch plate carrier.

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

Fig 5: Identifying Clutch Retaining Bar T10303

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• To prevent the : T10303  from rotating in place, do not turn the dual clutch.

-- Pry out the circlip -2- using a screwdriver -1- in direction of -arrow-.

Fig 6: Identifying Circlip Pried Out Using A Screwdriver

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-- Remove the drive plate in direction of -arrows-. To do so, carefully pry the drive plate out of the outer clutch plate carrier teeth using a screwdriver if necessary.

Fig 7: Identifying Clutch Cover And Clutch

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Tip:

• If the inner clutch plate carrier is removed or raised, the plates can slip. The dual clutch can then no longer be adjusted correctly.

-- Move the drive plate to the side.