Clutch, Installing And Adjusting: Notes

WARNING: This page is about a different car, the 2008 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Avoid removing or lifting the clutch pack carrier because the discs can rotate.

Short Description

Turn the transmission vertically in the assembly bracket to ensure a correct clutch axial play adjustment.
Securely clamp the transmission in the holding fixture VW 313 or the engine and transmission holder VAS 6095 and do not rotate. Refer to TRANSMISSION, TRANSPORTING AND SECURING ON ASSEMBLY STAND .
Ensure that the large clutch pack carrier has not slipped out of the bottom disc
The pump shaft or oil pump must be removed
Do not install any wavy circlips

Special tools and workshop equipment required

Retaining bar T10303

-- Place the T10303 on the cover seat

Fig 1: Identifying Retaining Bar T10303 On Cover Seat

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Clutch Installing

Fig 2: Removing Clutch

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-- Have a second technician hold the T10303

Fig 3: Holding Retaining Bar T10303

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-- Carefully remove the clutch cover from the clutch and lay aside.

Fig 4: Identifying Clutch Cover And Clutch

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CAUTION:

Avoid removing or lifting the clutch pack carrier because the discs can rotate.

-- Find the 2 mm thick circlip out of the ten circlips delivered and install it temporarily.

Fig 5: Identifying Temporary Ring Installed

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Perform two measurements before removing the circlip:

First Measurement

The T10303 remains on the cover seat.

-- Install the VW 387 on the transmission flange.

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

Fig 6: Identifying Dial Gauge Button And Input Shaft

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-- Adjust the dial gauge pretension to 0.

-- Raise the clutch up as far as the stop and note the measurement.

Second Measurement

The T10303 remains on the cover seat.

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

Fig 7: Identifying Gauge Button Placed On Hub On Large Clutch Pack Carrier

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NOTE:

The plunger must not rest on the circlip.

-- Readjust the dial gauge pretension to 0.

-- Raise the clutch up as far as the stop again and note this measurement as well.

-- Calculate the final circlip to be installed using the following formula:

Second measurement minus first measurement plus 1.85 mm = thickness of circlip to be installed.

-- Note the result.

The remaining nine circlips are staggered in 0.1 mm increments.

-- Measure all the circlips and determine the one that is the closest match to the result.

-- Remove the 2 mm circlip and replace with the calculated one.

-- Dispose of all the remaining circlips and the 2 mm circlip

NOTE:

Circlips must only be installed one time.

-- Insert the pump shaft.

Fig 8: Inserting Pump Shaft

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-- Insert the clutch cover so the tab aligns with the mark.

Fig 9: Identifying Clutch Cover Location

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-- Remove the T10303.

-- Install clutch cover. Refer to INSTALLING .

-- After installing the transmission, perform a Direct Shift Gearbox (DSG) mechatronic basic measurement.