Dual Clutch, Installing

Special tools and workshop equipment required 

• Dial Gauge Holder: VW387 
• Dial Gauge - 0-10mm: VAS6079 
• Retaining Pin: T10524 
• Intake Manifold Release Tool: T10526 

Tip

• The drive plate must remain engaged between the teeth of the outer clutch plate carrier.
• If the drive plate is loosened, the clutch plates in the dual clutch can slip out of place. The dual clutch may not be correctly set during installation under certain circumstances.

Installing 

-- 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.

-- Turn the piston ring by hand. They must move freely and must not stick.

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-- Pay attention that the piston rings -1, 2, 3 and 4- are seated correctly. The ends of the ring -arrows- and the piston rings -1 and 3- must align with each other.

-- The ends of the ring -arrows- of the piston rings -2 and 4- should be 180° offset to the ends of the ring of the piston rings -1 and 3- and align.

Important! Drive Plate Position

-- Before installing check if a mark -arrow- is on the dual clutch.

-- If no mark is present, apply a color coding of the drive plate and on the outer clutch plate carrier with a waterproof pen.

-- Insert the : T10524  -1-.

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• A second technician should hold the : T10524  when inserting the dual clutch.

-- Carefully insert the dual clutch do not let it fall.

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-- If necessary insert by lightly turning the clutch.

The dual clutch is in the correct installation position when the : T10524  has very little play.

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• The retaining pin remains there until clutch end cover is installed.
• The dual clutch must not be turned any more now, otherwise the : T10524  could be twisted in its position.

-- Pry out the circlip using the drive plate.

-- Place the : T10525  with : T10055  on the splines and carefully drive out the drive plate from its seat in direction of -arrows-.

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• The : T10524  must be held by a second technician when removing.

-- Carefully remove the drive plate from the dual clutch -arrows- and move to the side.

Determine the Shim for the Dual Clutch:

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• The : T10524  remains inserted.

-- Install the "old" circlip -arrow- temporarily.

Perform two measurements before removing the ring again.

First Measurement (Axial Play of the Shaft)

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-- Install the : VW387  on the transmission flange.

-- Place the -dial gauge button- on the input shaft.

-- Adjust the -dial gauge- pretension to 0.

-- Pry up the dual clutch using the T-Handle Hook: 3438  in the direction of the -arrow- sharply upward all the way and note the measurement result.

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-- Name this value "A".

• The value is needed later for a measurement check for this reason retain the value "A" until the last measurement.

Second Measurement

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• The Retaining Pin: T10524  remains inserted.

-- Place the gauge button -on the hub of the large clutch plate carrier-.

• The plunger must not rest on the circlip.

-- Readjust -dial gauge- pretension to 0.

-- Raise the double clutch upward sharply until stop and note the measurement.

-- Name this value "B".

Now Which Shim will be Installed is Calculated:

-- Use this formula:

Measured value "B" - measured value "A" - 0.11 = thickness of the shim to be installed

-- Write down the measurement result.

The shims are staggered in 0.05 mm steps.

-- Measure the shim and determine the shim which comes the closest to the result.

Tip

• The next largest shim is always used, never install a smaller shim.

Example:

Determined Dimension of the Shim	New Shim
1.28 mm	1.3 mm
1.26 mm	1.3 mm

-- Remove the old circlip -arrow-.

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-- Install the determines shim.

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Measurement Check

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Another measurement check is performed to check the shim. To do so proceed as follows.

• The : T10524  remains inserted.

-- Install the old circlip -arrow- again.

-- Place the gauge button -on the hub of the large clutch plate carrier-.

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• The test probe must contact the shim -1-.

-- Readjust -dial gauge- pretension to 0.

-- Raise the double clutch upward sharply until stop and note the measurement.

-- Name this value "C".

Now Which Shim will be Installed is Calculated:

-- Use this formula:

Measured value "C" - measured value "A" = specified value

The specified value must be between 0.05 to 0.12 mm.

If the specified value is not reached then reach the specified value by installing a thicker or thinner shim.

-- Install a new circlip -arrow-.

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-- Insert the drive plate into the dual clutch.

• When installing pay attention that the mark on the drive plate aligns with the mark on the outer clutch plate carrier -arrows-. Make note of markings that have been changed retrospectively.

-- Have a second technician hold the : T10524  in its position and push slightly outward.

-- Using the : 40-21  and a plastic mallet carefully drive the drive plate in its position.

-- Install the new drive plate circlip.

-- Push the circlip on the opening starting clockwise in the end position.

• The circlip must be completely engaged.

-- Check the exact installation position of the circlip and that the circlip is engaged using a screwdriver.

-- Now remove the : T10524  between the dual clutch and the housing.

-- Install the clutch end cover. Refer to CLUTCH END COVER, REMOVING AND INSTALLING .