Direct Shift Gearbox Overview

Short Description 

• The Direct Shift Gearbox (DSG R) clutch contains 2 toothed plate packs. The outer, larger disc pack is called "K 1" (clutch 1). The "K 1" shifts reverse gear and 1st, 3rd, and 5th gears. The inner, smaller "K 2" (clutch 2) shifts 2nd, 4th and 6th gears.
• Assembling the DSG R clutch requires special care, because all the components were balanced to each other at the manufacturer. When positioning the components during installation, do not rotate them from their original position, otherwise imbalances will occur, reducing the shift comfort and the life span.

Replacement Part Package 

Fig 1: Identifying Multi-Plate Clutch Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. DSG R Clutch and Lock Ring 
   CAUTION:

   • The drive plate (upper part of the DSG R clutch) of a new clutch is not secured with the lock ring, it only sits taut in the clutch.
   • The drive plate must be engaged between the teeth of the exterior clutch pack.
   • If the drive plate is loosened, the clutch discs in the DSG R clutch can slip out of place and the DSG R clutch may not be correctly set during installation under certain circumstances.
2. Circlips 
   • Qty. 10, with various thicknesses for adjusting.
   • When installing the clutch, the thickness of the circlip must be determined. Refer to CIRCLIP FOR CLUTCH .
3. Clutch End Cover 
4. Clutch End Cover Lock Ring 

Individual Parts of the Disassembled DSG R Clutch

Fig 2: Exploded View Of Clutch Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. DSG R Clutch/Clutch Housing 
   • Outer clutch pack carrier.
2. Seals 
   • Quantity: 4
3. Inner Clutch Pack Carrier 
   • Do not remove.
     CAUTION:

     Do not lift or remove the inner clutch pack carrier, under any circumstances. The clutch discs could rotate themselves.

4. Outer Discs 
   • Quantity: 4
5. Inner Discs 
   • Quantity: 4
6. Thrust Washer 
7. Lock Ring 
   • If the lock ring was removed in order to install the discs, it should be replaced with a new lock ring of the same thickness.
8. Lock Ring 
   • Reset after installing a new clutch. Refer to CIRCLIP FOR CLUTCH .
9. Drive Plate 
10. Lock Ring 
    • Always replace.