Dual Clutch

Dual Clutch

Special tools, testers and auxiliary items required

• Additional Hooks (2) (10 - 222 A /2)

• Shop Crane -Load Cap=700-1200kg (VAS 6100)

• Pulling Hook (T20143/2)

• Lifting Device (T40123 A)

• Assembly Pin (T40199)

• Engine and Transmission Holder (VAS 6095)

Removing






• Secure the transmission to the (VAS 6095). Refer to => [ Securing on Engine and Transmission Holder ] Securing On Engine and Transmission Holder.

- Remove the flywheel. Refer to => [ Flywheel ] Flywheel.

- Drain the ATF. Refer to => [ ATF, Draining ] ATF, Draining.

- Remove the input shaft seal using the (T20143/2).

- Remove the bolts - 1 through 5 -.






- Turn the inside of the (VAS 6095) so that it is vertical.






- Push the sleeve (T40123 A/1) onto the input shaft.

- Position the (T40123 A) on the input shaft.

• The edge - arrow - of the lifting device must grip under the (T40123 A/1).

- Close the lifting device and tighten the knurled nut - 1 - to approximately 20 Nm.

- Make sure the lifting device fits securely on the input shaft.

- Connect the (T40123 A) to the (10 - 222 A /2) and attach to the (VAS 6100).






- Carefully remove the dual clutch out of the transmission housing.

- Lay the dual clutch and cover on a soft surface so that the thin rib - arrow A - does not get damaged.






- Remove the locking ring - arrow - with locking ring pliers.






- Remove the clutch cover - 2 - from the dual clutch - 1 -.






• If the clutch cover does not come off, gently strike the input shaft with a rubber hammer while a second technician lifts the clutch cover by hand.






• Be careful not to damage the thin rib - arrow A - when doing this.

Installing

Install in reverse order of removal. Note the following:

• Replace the O-ring and the circlip.

- Clean the sealing surface on the clutch cover.

- Turn the rectangular rings - B - on the hub and check for ease of movement and axial play.

• If the rectangular rings do not move easily, then the dual clutch must not be installed.

- Clean the transmission housing around the dual clutch and the sealing surface.






• Make sure no dirt can fall into the transmission while cleaning.

- Install the (T40199) into the threaded hole in the transmission housing as illustrated.

- Check the hole - arrow - in the transmission for wear grooves.






- Coat the O-ring - C - and hub - B - on the dual clutch with ATF.






- Install the dual clutch into the transmission housing. Using short lifting/turning motions, allow the input shaft to engage into the ATF pump splines and transmission shafts as illustrated.






• The dual clutch is installed correctly when the clutch cover O-ring noticeably contacts the edge of the transmission housing.








• Do not let the O-ring get caught when installing.

• Always follow the tightening sequence when tightening the clutch cover bolts - 1 through 5 - (=> [ Clutch Cover Tightening Specification and Sequence ] Flywheel and Dual Clutch Assembly Overview).

- Tighten the clutch cover bolts - 1 through 5 - to the tightening specification and sequence. Refer to => [ Clutch Cover Tightening Specification and Sequence ] Flywheel and Dual Clutch Assembly Overview.

- Replace the input shaft seal. Refer to => [ Input Shaft Seal ] Input Shaft Seal.

- Install the flywheel. Refer to => [ Flywheel ] Flywheel.

- Fill the ATF after installing the transmission.

• After replacing the dual clutch, the corresponding "Guided Functions" must be performed using the vehicle diagnostic tester.