Installing Double Clutch

Information 

• Do not allow particles of dirt to get into the transmission. 

1. Check plain bearing bushing -1-  in the transmission for scoring and replace it if damaged.

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   Plain bearing bushing

2. Position double clutch cover -1-  and install new  circlip -2-  .

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   Circlip on double clutch cover

   Information 

   • Do not crush new O-ring. 

   Information 

   • Plain compression rings must move freely. 
3. Prepare double clutch for installation.
   1. 3.1  Install new  O-ring on double clutch cover
   2. 3.2  Turn plain compression rings -2-  on the hub and check for smooth operation and axial play.
   3. 3.3  Coat O-ring on double clutch cover -1-  and hub with ATF.

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      Double clutch

4. > T40199 - Guide pins-1-  must be screwed in.

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   T40199 Guide pins

5. > T40123B - Lifting equipment  must be fitted on the double clutch.
   1. 5.1  Push T40123 A/1 - Sleeve  onto the drive shaft.
   2. 5.2  Fit puller of the > T40123B - lifting equipment  .
      1. 5.2.1  Position the puller so that it engages under T40123 A/1 - Sleeve. 
      2. 5.2.2  Close the puller and tighten knurled nut.
   3. 5.3  Check that the > T40123B - lifting equipment  is fitted securely on the drive shaft.

      Information 

      The double clutch is fitted correctly if the O-ring on the double clutch cover is touching the edge of the transmission housing.

6. Install double clutch -1-  .

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   T40123B Lifting equipment with workshop crane

   1. 6.1  > T40123B - Lifting equipment-2-  must be engaged using > 10-222A/2 - additional hooks-3-  on the > VAS 6100 - workshop crane-4-  .
   2. 6.2  Insert double clutch -1-  into the transmission housing using > T40123B - lifting equipment  .
      1. 6.2.1  Position double clutch using > T40199 - guide pins  .
   3. 6.3  Allow the double clutch to engage in the splines of the ATF pump and transmission shaft using short lifting/turning movements.
7. > T40123B - Lifting equipment-1 -  must now be removed from the drive shaft -2-  .

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   T40123B Lifting equipment

   1. 7.1  Loosen knurled screw -5-  and open puller -4-. 
   2. 7.2 T40123 A/1 - Remove sleeve -3-  from the drive shaft -2-  .
8. Secure double clutch cover -1-  .
   Fig 1: Double Clutch Cover Screws Tightening Sequence

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   Cover on double clutch

   1. 8.1  Screw in screws evenly by hand until the screw head is touching the clutch cover.
   2. 8.2  Tighten the crankshafts one after the other in steps of 90° until the clutch cover is touching the transmission housing.
   3. 8.3  Screw in and tighten screws -2 to 6-  .

      > Tightening - torque + 10 Nm (7.4 ftlb.)