Identify the Locking Ring for the DSG Clutch

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Fig 1: Identifying Circlip Temporarily Installed

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-- Find the 2 mm thick circlips in the replacement parts package.

NOTE:

For the initial measurement, temporarily insert 2 mm thick circlip. After the measurement has been determined, replace it with the final circlip.

-- Insert a 2 mm locking ring -arrow-.

First Measurement:

The Clutch Retaining Bar T10303 remains installed.

-- Install the Dial Gauge Holder VW 387 on the transmission flange.

Fig 2: Identifying Dial Gauge Button And Input Shaft

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-- Place the tip of dial indicator ion the input shaft and shown in the illustration.

-- Set the dial gauge with 2 mm preload to "0".

-- Raise the double clutch upward until stop and note the measurement.

Second Measurement:

The Clutch Retaining Bar T10303 remains installed.

-- Place dial gauge measuring tip on inner clutch pack carrier hub, as show in the illustration.

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

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NOTE: Do not place the measuring on the circlip.

-- Set the dial gauge with 2 mm preload to "0".

-- Raise the double clutch all the way up.

-- Read the measurement and note.

The new circlip will be determined according to the following formula:

Circlip = 2. Measurement - 1. Measurement + 1.85 = Thickness of the circlip to be installed.

-- Write down the result.

The new 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

NOTE: If the measurement determined for the new circlip is 2 mm, the circlip that was inserted temporarily remains installed.

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

Fig 4: Identifying Circlip Temporarily Installed

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-- Dispose of any remaining rings.

NOTE: Circlips must only be installed one time.

-- Insert pump shaft by raising shaft and turning slightly -arrow- so it engages completely in splines.

Fig 5: Inserting Pump Shaft

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-- Insert the drive plate into the DSG clutch.

Fig 6: Clutch Cover Location

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The protruding tab on the drive plate -arrow- must be installed between the marked teeth or the marking applied to the outer clutch pack carrier.

-- Install the new drive plate circlip.

Fig 7: Inserting Clutch Cover So That Tab Aligns With Mark

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Installed position: The drive plate tab and marked teeth or outer clutch pack carrier marking that was applied must lie between the ends of the circlip.

-- Using screwdriver, make sure the circlip is completely engaged.

-- Remove the Clutch Retaining Bar T10303 between the double clutch and the housing.

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