Clutch Engaging Mechanism, Adjusting: Procedure

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

The dual clutch is removed. Refer to DSG .
The transmission flange must be even so that it has a good surface for the ruler.
The DSG Transmission Mechatronic -J743- is installed in the transmission.

CAUTION:

Danger of damaging the dual clutch and other components.

The mount for the engaging lever and the entire mechanical system for the engaging bearing must be dry and free from oil and grease.

If Ball Stud Is Worn Down

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-- Remove the ball stud using pliers.

-- Install the new ball stud by hand. Use a plastic hammer and drift gently, if necessary.

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NOTE:

Tap the drift with the plastic hammer gently to avoid damaging the ball stud.

Continuation For All

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NOTE:

If dimension "B" was already measured, then step "2" of the measurement can be made now. Refer to CLUTCH ENGAGING MECHANISM, ADJUSTING .

-- Install the previous locking ring -arrow- for the outer input shaft.

Step 1: Measure Dimension "B" For Clutch "K 1" And "K 2".

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-- Place Ruler (2 pc.) :T40100 across the end of the shaft on the transmission flange.

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CAUTION:

There is the risk of incorrect measurements.

The Ruler (2 pc.) :T40100 should stay in this position for the following measurements. Do not move it or take if off.

-- Place the Digital Depth Gauge - 300mm :VAS6594 on top of the Ruler (2 pc.) :T40100 and position the depth slide on the outer input shaft.

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-- Set the depth gauge to "0".

-- Position the depth slide on the locking ring, as illustrated.

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-- Measure dimension "B₁ " on the locking ring in this position.

Example: measurement "B₁ " = 2.62 mm

-- Measure dimension "B₂ " on the opposite side of the locking ring.

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NOTE:

Do not measure on the end of the locking ring. The locking ring could get pushed away and this would invalidate the measurement.

Example: dimension "B₂ " = 2.58 mm

-- Calculate the mean value from "B₁ " and "B₂ ".

Formula: B + B2

Example:

2.62 + 2.582 = 2.60 mm
Result: dimension "B" = 2.60 mm

NOTE:

If the dual clutch is being installed according to this measurement, then it must be removed now. Refer to DSG .

-- Remove the locking ring -arrow- from the outer input shaft and throw it away.

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CAUTION:

Do not re-use the locking ring.

Step 2: Measure Dimension "A 1" For The Clutch Engaging Bearing "K 1" .

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-- Install the large engaging lever.

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CAUTION:

There is the risk of incorrect measurements.

Do not install the shim.

-- Make sure the engaging lever fits correctly.

-- Place the Gauge - Clutch Bearings :T10466 on the large engaging bearing. The flat side faces up

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-- Press and turn the Gauge - Clutch Bearings :T10466 to make sure it seats correctly on the engaging bearing.

The engaging bearing turns with the Gauge - Clutch Bearings :T10466 .

-- Place the Digital Depth Gauge - 300mm :VAS6594 on top of the ruler and position the depth slide on the outer input shaft.

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The Ruler (2 pc.) :T40100 lies straight across the transmission flange over the end of the shaft.

CAUTION:

There is the risk of incorrect measurements.

The Ruler (2 pc.) :T40100 should stay in this position for the following measurements. Do not move it or take if off.

-- Set the depth gauge to "0".

-- Position the depth slide on the Gauge - Clutch Bearings :T10466 , as illustrated.

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-- Measure dimension "A 1_a " on the Gauge - Clutch Bearings :T10466 .

Example: measurement "A 1_a " = 5.03 mm

-- Measure dimension "A 1_b " on the other side of the Gauge - Clutch Bearings :T10466 .

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Example: measurement "A 1_b " = 5.01 mm

-- Calculate the average value from dimension "A 1_a " and "A 1_b ".

Formula: A 1 + A 12

Example:

5.03 + 5.012 = 5.02 mm
Result: dimension "A 1" = 5.02 mm

Step 3: Measuring The Height Tolerance For The Engaging Bearing Of Clutch "K 1".

NOTE:

Using dimension "A 1" and dimension "B", calculate the height tolerance for clutch "K 1" engaging bearing as follows:

	Dimension "A 1"
-	Dimension "B"
=	Height tolerance for clutch "K 1" engaging bearing

Example:

5.02 mm - 2.60 mm = 2.42 mm
Result: height tolerance for clutch "K 1" engaging bearing = 2.42 mm

Step 4: Measuring The Clutch Tolerance For Clutch "K 1".

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-- Read the clutch tolerance value on the new clutch.

Example: clutch tolerance read on the clutch "K 1 = +0.2", as illustrated.
Result: clutch "K 1" clutch tolerance = + 0.20 mm.

Step 5: Measuring The Thickness Of Shim "SK 1".

NOTE:

Using the clutch tolerance of clutch "K 1", now the thickness of shim "SK 1" can be calculated as follows:

	Height tolerance for the engaging bearing "K 1"
-/+	Clutch tolerance for clutch "K 1"
=	Calculated thickness for shim "SK 1"

Example:

2.42 mm + 0.20 mm = 2.62 mm
Result: calculated shim thickness "SK 1" = 2.62 mm

-- Select the shim from the table using the part number -magnifying glass- on the shim and lay it nearby for installation.

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Calculated Shim Thickness mm	Available Shim Thicknesses in mm	Shim Part Number
1.21 to 1.60	1.50	0AM 141 383
1.61 to 1.80	1.70	0AM 141 383 A
1.81 to 2.00	1.90	0AM 141 383 B
2.01 to 2.20	2.10	0AM 141 383 C
2.21 to 2.40	2.30	0AM 141 383 D
2.41 to 2.60	2.50	0AM 141 383 E
2.61 to 2.80	2.70	0AM 141 383 F
2.81 to 3.00	2.90	0AM 141 383 G
3.01 to 3.20	3.10	0AM 141 383 H
3.21 to 3.40	3.30	0AM 141 383 J
3.41 to 3.80	3.50	0AM 141 383 K

Example:

Result: calculated shim thickness "SK 1" = 2.62 mm
Selected shim thickness = 2.70 mm = part number 0AM 141 383 F

CAUTION:

There is a risk of damaging the clutch.

Later installed only this shim.

-- Remove the Gauge - Clutch Bearings :T10466 and large engaging lever.

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Step 6: Calculating Dimension "A 2" For Clutch "K 2" Engaging Bearing

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NOTE:

The guide sleeve upper section cannot be removed or installed separately. It is always removed and installed together with the guide sleeve lower section and the small engaging lever.

Note the Following When Installing A New Engaging Lever >>K 2<< :

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A new engaging lever >>K 2<< with guide sleeve upper and lower sections are in their transportation position when they are delivered -illustration-. It is necessary to first move them into their installation position before installing them.

Bringing the engaging lever >>K 2<< into the installed position as follows:

-- Hold the guide sleeve upper section with one hand. Turn the guide sleeve lower section in direction of -arrow- with the other hand until the sleeve moves freely.

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NOTE:

Hold both parts securely because a lot of force is needed to turn the guide sleeve lower section.

In the installed position, the holes in the guide sleeve lower section are at a right angle to the engaging lever and the sleeve can be moved freely.

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Continuation For All

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-- Install the small engaging lever with the upper and lower sections of the guide sleeve. Install new bolts and tighten them.

-- Install the small engaging bearing without the shim.

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CAUTION:

There is the risk of incorrect measurements.

Do not install the shim.

The small engaging bearing fits in only one position due to the 8 grooves.

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-- Turn the small engaging bearing to make sure it is installed correctly and fits correctly in the grooves.

-- Place the Gauge - Clutch Bearings :T10466 on the small engaging bearing. The flat side faces up

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-- Press and turn the Gauge - Clutch Bearings :T10466 to make sure it seats correctly on the engaging bearing.

The engaging bearing turns with the Gauge - Clutch Bearings :T10466 .

-- Place the Digital Depth Gauge - 300mm :VAS6594 on top of the ruler and position the depth slide on the outer input shaft.

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The Ruler (2 pc.) :T40100 lies straight across the transmission flange over the end of the shaft.

CAUTION:

There is the risk of incorrect measurements.

The Ruler (2 pc.) :T40100 should stay in this position for the following measurements. Do not move it or take if off.

-- Set the depth gauge to "0".

-- Position the depth slide on the Gauge - Clutch Bearings :T10466 , as illustrated.

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-- Measure dimension "A 2_a " on the Gauge - Clutch Bearings :T10466 .

Example: dimension "A 2_a " = 4.79 mm

-- Measure dimension "A 2_b " on the other side of the Gauge - Clutch Bearings :T10466 .

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Example: dimension "A 2_b " = 4.75 mm

-- Calculate the average value from dimension "A 2_a " and "A 2_b ".

Formula: A 2 + A 22

Example:

4, 79 + 4, 752 = 4.77 mm
Result: dimension "A 2" = 4.77 mm

Step 7: Measuring The Height Tolerance For The Engaging Bearing Of Clutch "K 2".

NOTE:

Using dimension "A 2" and dimension "B", calculate the height tolerance for clutch "K 2" engaging bearing as follows:

	Dimension "A 2"
-	Dimension "B"
=	Height tolerance for clutch "K 2" engaging bearing

Example:

4.77 mm - 2.60 mm = 2.17 mm
Result: height tolerance for clutch "K 2" engaging bearing = 2.17 mm

Step 8: Measuring The Clutch Tolerance For Clutch "K 2".

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-- Read the clutch tolerance value on the new clutch.

Example: clutch tolerance read on the clutch "K 2 = - 0.2", as illustrated.
Result: clutch "K 2" clutch tolerance = - 0.20 mm.

Step 9: Measuring The Thickness Of Shim "Sk 2".

NOTE:

Using the clutch tolerance of clutch "K 2", now the thickness of shim "SK 2" can be calculated as follows:

	Height tolerance for the engaging bearing "K 2"
-/+	Clutch tolerance for the clutch "K 2"
=	Calculated thickness for shim "SK 2"

Example:

2.17 mm - 0.20 mm = 1.97 mm
Result: calculated shim thickness "SK 2" = 1.97 mm

-- Measure the needed shim from the shims supplied and keep it close for installation.

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Calculated Shim Thickness mm	Available Shim Thicknesses in mm	Shim Part Number
0.31 to 0.90	0.80	WHT 005 518
0.91 to 1.10	1.00	WHT 005 518 A
1.11 to 1.30	1.20	WHT 005 518 B
1.31 to 1.50	1.40	WHT 005 518 C
1.51 to 1.70	1.60	WHT 005 518 D
1.71 to 1.90	1.80	WHT 005 518 E
1.91 to 2.10	2.00	WHT 005 518 F
2.11 to 2.30	2.20	WHT 005 518 G
2.31 to 2.50	2.40	WHT 005 518 H
2.51 to 2.70	2.60	WHT 005 518 J
2.71 to 3.30	2.80	WHT 005 518 K

Example:

Result: calculated shim thickness "SK 2" = 1.97 mm
Selected shim thickness = 2.00 mm

CAUTION:

There is a risk of damaging the clutch.

Later installed only this shim.

The adjustment is now completed and the small engaging lever is already installed.

-- Install the dual clutch. Refer to DUAL CLUTCH, INSTALLING .