Clutch End Cover: Installing

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

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 2: Clutch End Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Do not apply adhesive to inside of the clutch end cover.

-- Carefully remove the adhesive if it has already been applied!

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 3: Holding Clutch End Cover

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-- Clean the end of transmission shaft.

Clutch End Cover without Bushing:

Fig 4: Identifying Cover Delivered Without Bushing

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-- Place the Guide Sleeve T10302 on a level surface.

Fig 5: Guiding Cover Horizontally And Evenly Over Entire Sleeve

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

-- Remove the Guide Sleeve T10302 upward out of the clutch end cover.

-- Place the Guide Sleeve T10302 on the end of the DSG clutch shaft.

Fig 6: Cover Guided Horizontally Over Sleeve

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

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

Fig 7: Identifying Cover In Its Seat Pried With Screwdriver

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

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

-- Remove the Guide Sleeve T10302.

Clutch End Cover with Bushing (Assembly Aid):

Fig 8: Caution - Do Not Remove Bushing!

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-- Install the clutch end cover with bushing.

Fig 9: Identifying Cover With Bushing

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

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

Fig 10: 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 counter holding 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 11: Identifying Cover With Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Procedure for Both Clutch End Covers:

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

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

-- Perform basic setting. Refer to Vehicle Diagnostic Tester Guided Functions  .