Clutch End Cover, Removing And Installing: Installing

Fig 1: Attention: Never Oil Center Seal Or Touch With Hand

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Only hold the cover as shown.

Fig 2: Holding Clutch End Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Note the Following  Before Installing the Clutch End Cover:

The new clutch cover must not have any oil in the around the center seal and it must be dry.

-- If necessary, clean the sealing surface on the drive plate -arrow- thoroughly.

Fig 3: Clutch End Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

There must not be any stickers on the inside of the clutch end cover.

-- If there is, carefully remove the sticker.

Only coat outer edge of seal with oil.

-- Remove the clutch end cover from the replacement parts package, only touching cover on outer edge.

Fig 4: Holding Clutch End Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Clean the end of transmission shaft.

Clutch End Cover without Bushing 

Fig 5: Identifying Cover Delivered Without Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the Clutch Cover Plate Guide Sleeve:T10302  on a level surface.

Fig 6: Guiding Cover Horizontally And Evenly Over Entire Sleeve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- To form the inner seal to the new clutch end cover, the guide clutch end cover with outer side down evenly and horizontally over the Clutch Cover Plate Guide Sleeve:T10302  .

-- Remove the Clutch Cover Plate Guide Sleeve:T10302  upward out of the clutch end cover.

-- Place the Clutch Cover Plate Guide Sleeve:T10302  on the end of the S-tronic clutch shaft.

Fig 7: Cover Guided Horizontally Over Sleeve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide the clutch end cover with outer side up horizontally over the Clutch Cover Plate Guide Sleeve:T10302  and press it evenly into the seat.

-- If necessary, carefully pry clutch end cover into seat with a screwdriver -arrow-, as illustrated until it is possible to install the shaft ring.

Fig 8: Identifying Cover In Its Seat Pried With A Screwdriver

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install clutch end cover circlip in transmission housing by counterholding circlip on the opposite side so it remains in its groove.

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

-- Remove the Clutch Cover Plate Guide Sleeve:T10302  .

Clutch End Cove with Bushing (Assembly Aid): 

Fig 9: Caution - Do Not Remove Bushing!

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the clutch end cover with bushing.

Fig 10: Identifying Cover With Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push the clutch end cover evenly into the seat.

-- If necessary, carefully pry clutch end cover into seat with a screwdriver -arrow-, as illustrated until it is possible to install the shaft ring.

Fig 11: Identifying Cover In Its Seat Pried With A Screwdriver

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install clutch end cover circlip in transmission housing by counterholding circlip on the opposite side so it remains in its groove.

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

-- Remove the bushing (assembly aid):

Fig 12: Identifying Cover With Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Continuation for Both Clutch End Covers 

-- Install the transmission. Refer to TRANSMISSION, INSTALLING .

-- Fill with transmission fluid. Refer to TRANSMISSION FLUID, DRAINING AND FILLING .

-- Perform the basic setting. Refer to Vehicle Diagnostic Tester.