CIRCLIP For Clutch

WARNING: This page is about a different variant/trim than selected.

Identify the circlip for the clutch

Fig 1: Identifying Temporary Ring Installed

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Select the 2 mm thick circlip from the circlips delivered and install it -arrow-.

NOTE:

This circlip is temporarily installed for the measurement of the axial play.

First Measurement:

The retaining bar -T10303- remains installed.

-- Install the dial gauge holder -VW 387- to the transmission flange.

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

Fig 2: Identifying Dial Gauge Button And Input Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Adjust the dial gauge pretension to 0.

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

Second Measurement:

The retaining bar -T10303- remains installed.

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

Fig 3: Identifying Gauge Button Placed On Hub On Large Clutch Pack Carrier

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The tip of the dial may not be placed 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

Now the calculation will be made to determine which of the remaining nine circlips will be installed:

-- Use this formula:

2nd measured value - 1st measured value + 1.85 mm = Circlip thickness

-- Write down 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

Determined measurement for the new circlip	New circlip
2.27 mm	2.3 mm
2.24 mm	2.2 mm

-- Remove the 2 mm circlip and replace it with the circlip that was measured.

Fig 4: Identifying Temporary Ring Installed

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Dispose of all the other remaining circlips and the 2 millimeter circlip.

NOTE:

Circlips must only be installed one time.

-- Insert the pump shaft.

Fig 5: Inserting Pump Shaft

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NOTE:

The pump shaft must be slightly lifted and rotated -arrow- in order for it to completely slide into the splines.

-- Insert the drive plate into the clutch.

Fig 6: Locating Clutch Cover

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The protruding tab of the drive plate must be positioned between the color marked teeth of the outer clutch pack carrier. Make note of the marks that have been changed retrospectively.

-- Install the new drive plate lock ring.

Fig 7: Identifying Clutch Cover Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The lock ring must be installed so that the tab of the drive plate and the color marked teeth of the outer clutch pack carrier are positioned between both ends of the lock ring.
The lock ring must be completely engaged.

-- Check the exact installed position of the lock ring and that the lock ring is engaged using a screwdriver.

-- Now remove the retaining bar -T10303- from between the clutch and the housing.

-- Install the clutch end cover. Refer to CLUTCH END COVER, INSTALLING .