Removing Double Clutch

1. Fit >9932 - gear support-1-  on the double clutch transmission with the help of another person.

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   Gear support 9932 (shown on 992)

   Tool overview

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   Tool overview for removing transmission (shown on 992)

   1	> VAS 6832 - Master Gear unit elevating platform
   2	> 9932 - Gear support
   3	> VAS 6100 - service crane

   NOTE: Mechanical overload of components

   • Component will be damaged irreparably

     → Observe guidelines for assembly and disassembly

2. Secure the transmission with >9932 - gear support  on assembly support >VAS 6095A - engine and gearbox bracket  .
3. Clean the cover and transmission bell housing to prevent dirt from falling in.
4. Remove circlip for clutch cover -1-  using pliers or a screwdriver.

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   Circlip for clutch cover

5. Pull off cover with >P90014/2 - spindle  .
   1. 5.1 Push spindle >P90014/2 - spindle-1-  onto the input shaft -2-  with the groove.

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      Positioning spindle

      Information 

      The use of spacer cylinders in the >P90014/1 - counter-hold tool  depends on the model line

      Check tool information and embossed tool number.

   2. 5.2 Position counter-hold tool >P90014/1 - counter-hold tool-1-  with the help of another person and secure with four screws -2-  .

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      Securing counter-hold tool (illustration shows only one side)

   3. 5.3 Screw nut -2-  with ball bearing -3-  onto the >P90014/2 - spindle  .
   4. 5.4 Turn nut -2-  clockwise using an open-ended wrench (a/f 30) and counter at the spindle using an open-ended wrench (a/f 17).

      After a few turns, check opening noise of the cover.

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      Removing clutch

   5. 5.5 If the cover is sticking, heat the transmission bell housing evenly around the cover using a hot-air gun.
   6. 5.6 Turn the nut -2-  three more turns to loosen the clutch correctly.
   7. 5.7 Remove counter-hold tool >P90014/1 - counter-hold tool  with the help of another person.
6. Remove clutch using >P90014/3 - holder-1-  .

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   Gripping and removing clutch

   1. 6.1 Secure gripper with spring -3-  on the shaft.
   2. 6.2 Turn the lever clockwise to tension it -2-  .
7. Connect gauge >VAS 6594 - depth gauge-3-  to depth gauge bridge VAS 6594/2 -2-  .
8. Set >VAS 6594 - depth gauge-1-  on transmission housing -2-  to zero.

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   Setting depth gauge to zero

9. Remove washer on main shaft -4-  and measure adjustment dimension -LHD vehicle -  from transmission housing flange to ring seat using a gauge >VAS 6594 - depth gauge  .

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   Depth gauge and washer

10. Enter dimension S  in a log and determine washer thickness using the following table.
    1. 10.1 Determine washer thickness.
    2. 10.2 Select a new  washer -5-  from the washer set.
    3. 10.3 Check washer using a commercially available micrometer.
    4. 10.4 Place washer over the main shaft -4-  .

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New washer