Attach protective cap (040) to clutch input shaft (2).
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- Press ball bearing (12) into clutch housing (1); to do so, use
drift 711 589 17 15 00.
When replacing clutch housing (1).
Support clutch housing (1) at opposite bearing side.
The clutch housing (1) will otherwise be damaged when it is pressed in.
Observe the installation position (the lettering on the ball bearing (12) must face upward).
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- Replace radial shaft sealing ring (11) on clutch housing (1); to do so, use
drift 711 589 01 15 00.
Up to transmission end number 004219, no chamfer is incorporated in the clutch housing (1); extreme care must therefore be taken when installing the radial shaft sealing ring (11).
The radial shaft sealing ring (11) will otherwise be damaged.
As of transmission end number 004220, a chamfer is incorporated in the clutch housing (1); this chamfer makes installation of the radial shaft sealing ring (11) easier.
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- Check that disk spring (4) is seated correctly.
If the disk spring (4) is installed incorrectly (left picture), there will be a gap to the clutch (arrow).
If the disk spring (4) is installed correctly (right picture), there is no gap to the clutch.
- Clean sealing surface (5) of differential housing (8) using Loctite cleaning spray.
The sealing surface (5) must be clean, dry and free of dust and grease.
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- Apply Loctite sealant uniformly to sealing surface (5) of differential housing (8).
Sealant should be applied only to the specified sealing surface (5), in the form of a bead measuring 2 to 3 mm in height and width. The sealant bead must not be spread. Use only the sealant indicated in the repair materials. Mount the differential housing within 10 minutes after application of the sealant.
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- Carefully place clutch housing (1) onto differential housing (8).
When installing the clutch housing (1), do not allow transmission oil to drip onto the previously-applied sealant bead.
Leaks can occur otherwise.
Align with the clutch input shaft. Owing to the disk spring (4) on the dual clutch, the clutch housing (1) does not lie flush against the differential housing (8). A gap of approx. 1 to 2 mm is acceptable and can be pulled together using the bolts. It is permissible to use a soft face hammer to carefully knock all the way around the clutch housing (1).
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Remove protective cap (040).
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- Manually screw in aluminum bolts M8x38 (3, 16 each) round the circumference until greater resistance becomes noticeable.
Install new aluminum bolts M8x38 (3).
- Tighten aluminum bolts M8x38 (3)
.
They are tightened in a crosswise sequence.
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- Fit caps (2, 3 each) into clutch housing (1).
Replace caps (2).
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Attach lifting device (010) to clutch housing, lift differential housing (01) using a hoist and position so that it is horizontal by pushing
lifting device (010) over elongated holes.
Use the fastening points (a) on the
lifting device (010).
Use the fastening points (b) on the clutch housing (1).
- Lift differential housing (01) further using hoist until it is possible to see into differential housing (01) from below.
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- Install clutch hydraulic unit connector (6) into opening of differential housing (01).
When replacing clutch hydraulic unit.
Install in the correct position. (Pay attention to the notch (c).).
- Install clip of clutch hydraulic unit connector (6).
When replacing clutch hydraulic unit.
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