Dual Clutch, Installing: Installing
Danger of damaging the dual clutch and other components.
- The position of the engaging bearings must be adjusted correctly.
Adjusting the engaging bearings can only be performed prior to installing the dual clutch.
The position of the engaging bearing must be adjusted after completing the following:
- The dual clutch was replaced.
- The engaging levers were replaced.
- The ball stud for the "K 2" engaging lever was replaced.
- The engaging bearings were replaced.
It is necessary to adjust the position of the "K 1 and K 2" engaging bearings first if one of the above mentioned procedures was performed. Refer to CLUTCH ENGAGING MECHANISM, ADJUSTING .
Continue with assembling only when the adjustment is correct.
The removed shims can be used again if no new parts were installed.
Only one shim per engaging bearing can be installed.
- Clutch components must have no oil or grease on them when being installed.
Danger of causing damage to the dual clutch adjusting tool.
- The dual clutch is self-adjusting. Vibrations can affect the adjusting tool. Be careful not to drop the dual clutch into the transmission when installing.
Requirement:
- The clutch engaging mechanism is installed. Refer to CLUTCH ENGAGING MECHANISM, REMOVING AND INSTALLING .
-- Turn back the spindle on the Puller - Clutch :T10373 .
-- Install the dual clutch into the transmission using Puller - Clutch :T10373 , as illustrated.
-- Position the Support Bridge :T1032 parallel to the transmission flange, as illustrated.
-- If necessary, even out the gaps, for example, using Subframe Bushing Assembly Tool Kit -Assembly Tool 5 :T10356/5 from the Subframe Bushing Assembly Tool Kit :T10356 .
-- Tighten the bolts -A- hand-tight.
Secure the bolts -A- with a nut, if needed.
-- Push on the dual clutch until it stops.
Keep hand on the dual clutch while pressing it on. A slight >>vibrating<< should be felt. Vibrating means the dual clutch is being pushed onto its press-fit. It can also be felt when the dual clutch has reached its stop.
-- Hold the new locking ring with locking ring pliers, as illustrated.
- Installed position: narrow ends of the locking ring at the top.
-- Install the circlip -arrow-
The dual clutch is not pressed correctly on the stop if the locking ring cannot be installed.
-- Turn the dual clutch against the Puller - Clutch :T10373 by hand without using any other tools so that it can move into its working position in direction of -arrow-.
The dual clutch sits on the stop at the bottom of the input shaft. This is not its optimal position.
The dual clutch should be pulled up just far enough until it touches the locking ring.
Only turn it by hand. This way the dual clutch slides against the locking ring. Do not use any other tool.
-- Install the hub.
- The hub as a single >>large tooth<< -arrow- and fits in only one position.
- The large tooth has a marking on the engine side.
-- Insert the locking ring -arrow-.
- The end of the locking ring must face the >>nose<< on the dual clutch.
-- Turn the dual clutch by hand. The dual clutch should turn without any problem.
Remove the dual clutch if it is difficult to turn or if it grinds against the clutch plates while being turned. Refer to DSG .
Check the installed position of the shims -arrows-.
The shims must fit correctly and must not be damaged.
It is possible there was a calculation error. Check the measurements one more time. Refer to CLUTCH ENGAGING MECHANISM, ADJUSTING .
If there was no error, then it is possible the dual clutch shifted during transportation/assembly. In this case it is necessary to install a new dual clutch. Then it is necessary to adjust the position of the engaging bearing again. Refer to CLUTCH ENGAGING MECHANISM, ADJUSTING .
-- Remove both plugs and install the vent caps -arrow A and B-.
The vent cap -arrow A- on the Mechatronic will get damaged when being removed and must be replaced.
-- Dispose of any extra shims.
-- Perform a Complete Basic Setting using the Vehicle Diagnostic Tester Guided Functions after installing the transmission.