Dual Clutch, Installing

WARNING: This page is about a different car, the 2023 Volkswagen Arteon. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Dial Indicator Holder:VW 387

Fig 1: Dial Gauge Holder
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Dial Indicator - 0-10mm:VAS 6079

Fig 2: Dial Gauge
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Retaining Bar:T10524

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Thrust Piece:T10526

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

The drive plate must remain engaged between the teeth of the outer clutch plate carrier.
If the drive plate is loosened, the clutch plates in the dual clutch can slip out of place. The dual clutch may not be correctly set during installation under certain circumstances.
Do not remove or lift the clutch pack, not even a small amount! The clutch plates could rotate themselves.

Brief Description

To remove and install the clutch, the transmission must be securely mounted on the assembly stand in a vertical position.
The large plate carrier is inserted in all clutch plates in the dual clutch. It must not be slid out of the lowermost slat.

Installing

-- Use special caution when removing the dual clutch from the packaging.

Do not remove or lift the clutch pack, not even a small amount. The clutch plates can rotate themselves.

-- Turn the piston ring by hand. They must move freely and must not stick.

-- Pay attention that the piston rings -1-, -2-, -3- and -4- are seated correctly. The ends of the ring -arrows- and the piston rings -1- and -3- must align with each other.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- The ends of the ring -arrows- of the piston rings -2- and -4- should be 180° offset to the ends of the ring of the piston rings -1- and -3- and align.

Important! Drive plate position

Fig 3: Important! Drive Plate Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Before installing, check if a mark -arrow- is on the dual clutch.

-- If no mark is present, apply a color coding of the drive plate and on the outer clutch plate carrier with a waterproof pen.

-- Insert the Retaining Pin:T10524 -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A second technician should hold the Retaining Pin:T10524 when inserting the dual clutch.

-- Carefully insert the -dual clutch- ; do not let it fall.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If necessary insert by lightly turning the clutch.

The dual clutch is in the correct installation position when the Retaining Pin:T10524 has very little play.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The retaining pin remains there until clutch end cover is installed.

Do not turn the dual clutch any further, otherwise the Retaining Bar:T10524 could be twisted in its position.

-- Pry out the drive plate circlip -2- with a screwdriver -1- -arrow-.

Fig 4: Identifying Circlip Pried Out Using A Screwdriver

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The circlip is reinstalled. Do not dispose of.

-- Place the Puller: T10525 with Puller - Unit Injector: T10055 on the splines and carefully drive out the drive plate from its seat -arrows-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The Retaining Pin:T10524 must be held by a second technician when removing.

-- Carefully remove the drive plate from the dual clutch -arrows- and move to the side.

CAUTION:

Do not remove or lift the clutch pack, not even a small amount! The clutch plates could rotate themselves.

Determine the shim for the dual clutch:

The Retaining Bar:T10524 remains inserted.

-- Install the "old" circlip -arrow- temporarily.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Before this ring is disposed of, three measurements must be performed first.

First measurement (axial play of the shaft)

-- Install the Dial Indicator Holder:VW 387 on the transmission flange.

-- Place the -dial gauge button- on the input shaft.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Adjust the -dial gauge- pretension to 0.

-- Pry up the dual clutch using the T-Handle Hook:3438 in the -direction of the arrow- using force upward all the way and note the measurement result.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Name this value "A".

NOTE:

The value is needed later for a measurement check for this reason retain the value "A" until the last measurement.

Second measurement

The Retaining Bar:T10524 remains inserted.

-- Place the gauge button -on the hub of the large clutch plate carrier-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The plunger must not rest on the circlip.

-- Adjust the -dial gauge- pretension again to 0.

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

-- Name this value "B".

Now which shim will be installed is calculated:

-- Use this formula for this:

Measured value "B" minus the measured value "A" minus 0.11 = the thickness of the rings to be installed.

-- Write down the measurement result.

The adjusting rings are staggered in 0.05 mm increments.

-- Measure the shim and determine the shim which comes the closest to the result.

CAUTION:

The next largest shim is always used, never install a smaller shim.

Example:

Determined dimension of the shim	New shim
1.28 mm	1.3 mm
1.26 mm	1.3 mm

-- Remove the old circlip -arrow-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Do not dispose of the ring yet it will be needed again.

-- Install the determines shim.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Three measurements (check measurement)

Another measurement check is performed to check the shim. To do so proceed as follows.

The Retaining Bar:T10524 remains inserted.

-- Install the old circlip -arrow- again.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the gauge button -on the hub of the large clutch plate carrier-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The test probe must contact the shim -1-.

-- Adjust the -dial gauge- pretension again to 0.

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

-- Name this value "C".

Now the final shim which will be installed is calculated:

-- Use this formula for this:

Measured value "C" minus measured value "A" = specified value

The specified value must be between 0.05 to 0.12 mm.

If the specified value is not reached then reach the specified value by installing a thicker or thinner shim.

-- Install a new circlip -arrow-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the drive plate into the dual clutch.

Fig 5: Important! Drive Plate Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

When installing pay attention that the mark on the drive plate aligns with the mark on the outer clutch plate carrier -arrows-. Make note of markings that have been changed retrospectively.

-- Have a second technician hold the Retaining Bar:T10524 in its position and push it slightly outward.

-- Using the Bearing Installer - Differential Bearing:40-21 and a plastic mallet carefully drive the drive plate in its position.

-- Install the drive plate circlip.

-- Push the circlip on the opening starting clockwise in the end position.

The circlip must be completely engaged.

-- Check the exact installation position of the circlip and that the circlip is engaged using a screwdriver.

-- Now remove the Retaining Bar:T10524 between the dual clutch and the housing.

-- Install the clutch end cover. Refer to CLUTCH END COVER, REMOVING AND INSTALLING .