Multi-Plate Clutch

Multi-Plate Clutch

Special tools, testers and auxiliary items required

• Guide Sleeve (T10302)

• Retaining Bar (T10303)

• Clean the (T10302) before using, do not use any scratched sleeves.

Remove Clutch End Cover





- Drain the transmission fluid. Refer to => [ Transmission Oil, Draining, Changing and Filling ] Transmission Oil, Draining, Changing and Filling.

- Remove the transmission. Refer to 2.0L TFSI=> [ Transmission, Removing ] Transmission, Removing or 2.0L TDI CR => [ Transmission, Removing ] Transmission, Removing.

- Secure the transmission in vertical position to the engine/transmission holder. Refer to => [ Transmission, Securing in Engine/Transmission Holder ] Transmission, Securing In Engine/Transmission Holder.

- Replace the transmission fluid filter. Refer to => [ Transmission Fluid Filter ] Transmission Fluid Filter.

- Using a screw driver - 1 -, pry the circlip - 2 - out of the clutch end cover - arrow - and remove the circlip.





- Carefully pry the clutch cover - 2 - through the opening for the starter with a screw driver - 1 - or a pry bar - arrow - and remove the clutch cover.





Removing Multi-Plate Clutch

- Pry out the circlip - 2 - using a screwdriver - 1 -- arrow -





- Remove the drive plate - arrow -.





- Pry out circlip with a screwdriver or suitable pliers - arrow -.





• This circlip must be replaced and re-measured during installation.

- Remove the multi-plate clutch.





- After removing the multi-plate clutch, check the clutch bell for damage.

- Remove the pump shaft - A -.





• The pump shaft will first be used after the installation of the new clutch. Set aside the shaft until then.

Installing Multi-Plate Clutch


• The drive plate of a new clutch is not secured with the circlip, it only sits "taut" in the clutch.

• Thus, press the drive plate into the outer clutch pack carrier with both thumbs during the following steps.

• The drive plate must be engaged between the teeth of the exterior clutch pack.

• If the drive plate is loosened, clutch discs in multi-plate clutch can slip out of place. The multi-plate clutch may not be correctly set during installation under certain circumstances.

- Remove the circlip from the packaging.

- Take the clutch for the direct transmission from the packaging, to do so, press the drive plate into the outer clutch pack carrier with both thumbs.





- Secure drive plate in outer clutch pack carrier with the "old" circlip - A - from the removed clutch.





• Do not use the new circlip for this installation.

• The circlip must be installed so that the tab of the drive plate - arrow - and the color-marked teeth of the outer clutch pack carrier are positioned between both ends of the circlip.

- Check the bottom side of the multi-plate clutch to see if the 4 hub sealing rings are seated correctly and engage them in one another if necessary.





• The ends of the rings should not stand over one another.

- Set the (T10303) on the seat of the clutch cover, as shown in the image.





- Set the multi-clutch plate in the clutch bell for rotating and hub movements, do not let it fall in. To do this, press the drive plate into the outer clutch pack carrier with both thumbs - arrow -.





• A second technician should hold the (T10303).





• Retaining pin remains there until clutch end cover is installed.

• Multi-plate clutch must not be turned any more now, otherwise the (T10303) could be twisted in this position.

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





If no marking is available:

- Mark the location of the tab to the outer clutch pack carrier circumference with a waterproof marker as shown in the illustration.

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

• The (T10303) should be held firmly by a 2nd technician during both of the following steps.





- Pry the old circlip - 2 - using a screwdriver - 1 -- arrow -






Do not remove or lift the inner clutch pack carrier, under any circumstances. The clutch discs could rotate themselves.

- Remove the drive plate from the installed clutch - arrow -, if necessary, use a screwdriver to carefully pry it out of the teeth of the outer clutch pack carrier.





- Set the drive plate aside.

Setting the Circlip for Multi-Plate Clutch

- Of the included circlips, determine which one is 2 mm thick and install this circlip - arrow -.





• This circlip is temporary installed for the measurement of the axial play.

- Install the dial gauge holder (VW 387) on to the transmission flange.





- For the 1st measurement, place the dial gauge measuring tip on the input shaft as shown in the illustration.

- Position the dial gauge with 2 mm of preload and set it to "0".

- Lift the clutch upwards and note the results of the measurement (= input shaft axial play).

- For the 2nd measurement, place the dial gauge measuring tip on tab of the inner clutch pack carrier as shown in the illustration.





• The tip of the dial may not be placed on the circlip.

- Position the dial gauge with 2 mm of preload and set it to "0".

- Lift the clutch upwards again and note the result.

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

2. Measured value - 1. Measured value + 1.85 mm = Circlip thickness

The new circlips (02E 311 321) are staggered in 0.1 mm increments. Round to the closest number when selecting: Up to 0.049 is rounded down and from 0.05 on is rounded up.






- Remove 2.0 mm thick circlip that was inserted temporarily for the measurement and replace with circlip thickness just determined.





• If the new circlip has a thickness of 2 mm, the ring used for the measurement does not need to be removed.

• Please dispose of all other circlips.

• Circlips must only be installed one time.

- Insert pump shaft.





• The pump shaft must be slightly lifted and rotated - arrow - in order for it to completely slide into the splines.

- Insert the drive plate into the multi-plate clutch.





• The protruding tab of the drive plate must be positioned between the color-marked teeth of the outer clutch pack carrier. Make note of markings that have been changed retrospectively.

- Install new drive plate circlip.





• The circlip must be installed so that the tab of the drive plate and the color-marked teeth of the outer clutch pack carrier are positioned between both ends of the circlip.

• The circlip must be completely engaged.

- Check the exact location and engagement of the circlip with a screwdriver.

- Remove the (T10303) between the multi-plate clutch and housing.

Installing Clutch End Cover

• Replacing clutch end cover and circlip.

- Thoroughly degrease the running surface of the drive plate - arrow - for the seal of the clutch end cover.






Cleaning of the contact surfaces of the clutch end cover must be executed thoroughly, otherwise there may be leaks.

- Clean the contact surfaces for the outer seals of the clutch end cover.






• Do not touch the seal in the inner opening of the clutch end cover! The seal function is only provided if the surface of the seal in its new condition is absolutely free of oil!

• The clutch end cover may not be exposed to direct hammer hits. Disruptions to the inner area of the clutch end cover lead to malfunctions!

- Remove the new clutch end cover from the packaging. Here, only touch the outer edge of the clutch end cover as shown in the image, the seal in the inner opening of the cover may not be touched.





- If necessary, clean the end of the transmission shaft.

• Only coat outer edge of seal with oil.

• Always remove any labels present on the outside or inside of end cover.

- Place (T10302) on a level surface.





- The gasket in the middle of the clutch end cover must be preformed for installation, by guiding the new clutch end cover with outside facing down horizontally and evenly over the entire assembly sleeve.

- Then remove sleeve upward out of the clutch end cover and place the sleeve on end of clutch shaft.

- Guide clutch end cover with outside facing upward horizontally over the sleeve and at the same time, push onto seat.





- Place the clutch end cover carefully into place with a screwdriver, as shown in the image, until the new circlip can be installed.





- Install new end cover circlip in transmission housing.

• When doing this, always counter hold on the opposite side, if necessary, so that the circlip remains in the groove.

• Circlip must completely engage and be fully seated in groove.

- Check the exact location and engagement of the circlip with a screwdriver.

- Fill the transmission fluid. Refer to => [ Transmission Oil, Draining, Changing and Filling ] Transmission Oil, Draining, Changing and Filling.

- After installing the transmission through Guided Functions the Basic Setting executing vehicle tester.