Dual Clutch, Installing: Installing

WARNING: This page is about a different car, the 2017 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Risk of discs in double clutch slipping.

The drive plate of a new double clutch is not secured with the circlip, it only sits "taut" in the double clutch.
If the drive plate comes out of the outer clutch pack carrier teeth, the plates can slip. The double clutch can no longer be adjusted correctly.
To ensure multi-plate clutch discs do not slip, press drive plate into outer clutch pack carrier with thumbs during all of the following steps.

NOTE:

The drive plate circlip delivered in the replacement parts package will be installed later.

-- Remove the new drive plate circlip from packaging and lay it aside.

-- Take the DSG® clutch out of the packaging while doing so press the drive plate into the outer clutch pack carrier with both thumbs.

Fig 1: Identifying Clutch From Wrapping, Removal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the old drive plate locking ring -A- in the double clutch removed earlier.

Fig 2: Identifying Drive Plate Secured In Outer Clutch Pack Carrier With Old Circlip From Removed Clutch

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installed position: Drive plate tab and outer clutch pack carrier teeth marked in color must lie between ends of circlip.

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

-- On bottom side of double clutch, check whether hub sealing rings are seated correctly and engage them in one another if necessary.

Fig 3: Identifying Ring Installation Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installed position: the ends of the ring are offset to each other and not over one another.

-- Insert the :T10303 in the positions on the clutch end cover as shown in the illustration.

Fig 4: Identifying Clutch Retaining Bar T10303 Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Set the dual clutch using rotating and lifting movements into the clutch housing, but do not let it fall in. Press the drive plate into the outer clutch pack carrier with both thumbs in direction of -arrows- to install.

Fig 5: Placing Multi-Plate Clutch Into Clutch Bell Housing Using Rotational And Vertical Movements

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A second technician holds the :T10303 .

Fig 6: Identifying Clutch Retaining Bar T10303
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The bolt remains installed until clutch end plate is installed.

The DSG® clutch must not be turned any more now, otherwise the :T10303 could be twisted in its position.

-- Verify that the protruding tab -arrow- of the drive plate is positioned between the color-marked teeth of the outer clutch pack carrier.

Fig 7: Clutch Cover Location Alignment Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If there is no marking, mark location of drive plate to outer clutch pack carrier circumference for reinstallation with a waterproof marker as shown in the illustration.

NOTE:

When installing, the drive plate tab must be placed back on this marked location.

-- Remove the (old) locking ring -2- with a screwdriver -1- in direction of -arrow-.

Fig 8: Identifying Circlip Pried Out Using A Screwdriver

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 9: Identifying Clutch Cover And Clutch

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Risk of discs in double clutch slipping.

If the inner clutch pack carrier is removed or raised, discs can slip. The double clutch can no longer be adjusted correctly.

-- Remove the drive plate -arrows-. If necessary, carefully pry the drive plate out of outer clutch pack carrier teeth using a screwdriver.

-- Move the drive plate to the side.