Clutch, Installing And Adjusting: Notes

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

CAUTION:

The drive plate of a new clutch is not secured with the lock ring, it only sits "taut" in the clutch.
Thus, press the drive plate into the outer clutch pack carrier with both thumbs during the following steps.
The drive plate must be engaged between the teeth of the exterior clutch pack.
If the drive plate is loosened, clutch discs in the clutch can slip out of place. The clutch may not be correctly set during installation under certain circumstances.

-- Take the clutch out of the packaging by pressing the drive plate into the outer clutch pack carrier with both thumbs.

Fig 1: Removing Clutch From Wrapping

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Next, secure the drive plate in the externally toothed plate carrier with the "old" lock ring -A- from the removed clutch.

Fig 2: Identifying Drive Plate Secured In Outer Clutch Pack Carrier With Old Circlip From Removed Clutch

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Do not use the new lock ring that was delivered with the package.
The lock ring must be installed so that the tab of the drive plate -arrow- and the color marked teeth of the outer clutch pack carrier are positioned between both ends of the lock ring.

-- Check the bottom side of the multi-plate clutch to see if the 4 hub seals are seated correctly and engage them in one another if necessary.

Fig 3: Identifying Ring Installation Position

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The ends of the seals should not overlap one another.

-- Turn the seals one time. They must move freely and must not stick.

Fig 4: Locating Clutch Cover

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-- Verify that the protruding tab -arrow- on the drive plate is positioned between the color marked teeth of the outer clutch pack carrier.

If no mark is available:

-- Mark the location of the tab to the outer clutch pack carrier circumference with a waterproof marker as shown in the illustration.

When installing, the drive plate tab must be placed back on this marked location.

-- Place the retaining bar -T10303- in position on the clutch cover as shown in the illustration.

Fig 5: Identifying Retaining Bar T10303 On Cover Seat

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-- Set the clutch using a rotating motion into the clutch housing, but do not let it fall in. Press the drive plate into the outer clutch pack carrier with both thumbs -arrows- to install.

Fig 6: Placing Multi-Plate Clutch Into Clutch Bell Housing Using Rotational And Vertical Movements

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A second technician should hold the retaining bar -T10303-.

Fig 7: Identifying Retaining Pin T10303
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NOTE:

The retaining bar remains there until the clutch end cover is installed.

The clutch must not be turned any more, otherwise the retaining bar -T10303- could be twisted in its position.

-- Remove -arrow- and dispose of the old lock ring -2- using a screwdriver -1-.

Fig 8: Identifying Circlip Pried Out Using A Screwdriver

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CAUTION:

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

-- Remove the drive plate from the installed clutch -arrows-, if necessary, use a screwdriver to carefully pry it out of the teeth of the outer clutch pack carrier.

Fig 9: Identifying Clutch Cover And Clutch

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-- Move the drive plate to the side.