Clutch, Installing And Adjusting: Notes

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

CAUTION:

Avoid removing or lifting up the clutch pack carrier. Not even a little! The clutch discs could rotate themselves.

Requirements

The transmission must be turned vertically in transmission holder. This is the only position in which the clutch axial play can later be adjusted without complications.
The transmission must be clamped secure in the holding fixture VW 313 or in the engine and transmission holder VAS 6095. Refer to TRANSMISSION, TRANSPORTING AND SECURING TO ASSEMBLY STAND . Do not turn it.
The large lamella carrier is inserted in all clutch discs in the clutch. The large lamella carrier must not slip out of the lowest clutch disc.
The oil pump shaft is removed.
Do not install any wavy circlips

Installing

Special tools and workshop equipment required

Retaining Bar T10303

-- First, place the retaining bar T10303 on the cover seat.

Fig 1: Identifying Retaining Bar T10303 On Cover Seat

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Then insert the clutch, do not let it fall in.

Fig 2: Removing Clutch

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Do not install the clutch on the retaining bar T10303. The clutch is inserted with the cover as it was in the packaging.

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

Fig 3: Hold Retaining Bar T10303

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The retaining bar T10303 remains installed there until all other work is completed.

Only remove the retaining bar T10303 when instructed to do so. Not right now.

-- Remove the cover -arrow- from the clutch and move it to the side.

Fig 4: Identifying Clutch Cover And Clutch

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Avoid removing or lifting up the clutch pack carrier. Not even a little! The clutch discs could rotate themselves.

-- Select the 2 mm circlip -arrow- provided with all the circlips and carefully install it.

Fig 5: Identifying Temporary Ring Installed

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Perform two measurements before removing the circlip again.

First Measurement:

The retaining bar T10303 remains installed.

-- Install the dial gauge holder 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 retaining bar T10303 remains installed.

-- 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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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

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

-- Use this formula:

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

-- Note the result.

The remaining 9 circlips are sized 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 it with the circlip that was measured.

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

The circlips must only be installed one time.

-- Install the pump shaft.

Fig 8: Inserting Pump Shaft

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-- Install the clutch cover so that tab aligns with the mark -arrow-.

Fig 9: Clutch Cover Location

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-- Remove the retaining bar T10303.

-- Install the cover. Refer to CLUTCH COVER, INSTALLING .

When the installation is completed, the clutch is adjusted correctly.

After installing the transmission:

-- Perform a basic measurement on the DSG transmission Mechatronic -J743-.