Clutch, Installing and Adjusting
Clutch, Installing and Adjusting
CAUTION!
Avoid removing or lifting the clutch pack carrier even slightly! The clutch discs could rotate.
Short Description
• Transmission must be turned vertically in the assembly stand. This is the only position in which the clutch axial play can later be adjusted without complications.
• The transmission must be clamped secure in the holding fixture (VW 313) or in the engine and transmission holder (VAS 6095). Refer to => [ Transmission, Transporting and Securing to Assembly Stand ] Procedures. It must not be rotated.
• The large lamella carrier is inserted in all clutch discs in the clutch. The large lamella carrier must not slipped out of the lowest clutch disc.
• Oil pump shaft is removed.
• Do not install any wavy circlips.
Special tools, testers and auxiliary items required
• Retaining Bar (T10303)
- First place the (T10303) on the cover seat.
- Then insert the clutch, do not let it fall in.
Do not install the (T10303) on the clutch. The clutch is inserted with the cover as it was in the packaging.
- (T10303) should be held in place by a second technician when doing this.
The (T10303) remains installed there until all other work is completed.
Only remove the (T10303) when instructed to do so. Not right now.
- Carefully remove the cover from the clutch - arrow - and lay aside.
CAUTION!
Avoid removing or lifting the clutch pack carrier even slightly! The clutch discs could rotate.
- Determine the circlip with 2 mm thickness from all circlips supplied and install it temporarily.
Perform 2 measurements before removing the circlip again.
First Measurement
• (T10303) remains installed!
- Install (VW 387) onto the transmission flange.
- Place dial gauge button on input shaft.
- Adjust dial gauge pretension to 0.
- Lift clutch upward until it stops and note the measurement result.
Second Measurement
• (T10303) remains installed!
- Place gauge button on the hub on the large clutch pack carrier.
Plunger must not rest on the securing ring.
- Readjust dial gauge pretension to 0.
- Lift clutch upward again until it stops and note this result as well.
Now the calculation will be made to determine which of the remaining nine circlets will be finally installed:
- For this, use this formula:
Second measurement minus first measurement plus 1.85 mm = thickness of circlip to be installed
- Note this result.
The remaining nine circlips are staggered in 0.1 mm increments.
- Measure all circlips and then determine the circlip which matches your result.
- Remove the 2 millimeter thick circlip and replace with the determined circlip.
- Dispose of all other circlips remaining and the 2 millimeter thick circlip.
Circlips must only be installed one time.
- Install the pump shaft.
- Install clutch cover so that the tab aligns with the mark.
- Now remove the (T10303).
- Install the cover. Refer to => [ Clutch Cover, Installing ] Clutch Cover, Installing.
This concludes the installation, the clutch is correctly adjusted.
After installing transmission
- Perform basic measurement on the DSG Mechatronic (J743).
Special Care
Assembling the multi-plate clutch requires special care, because all of the components were balanced to each other at the manufacturer. Do no rotate them from their original position, otherwise imbalances will occur, creating diminished shift comfort and life span.
If clutch components slip out or clutch pack carriers were raised up:
use light rotating motions to reposition the large, and if necessary the small, clutch pack carrier in all of the inner clutches.
The clutch cover, especially, should always be installed in the same position, as it was when the new clutch was delivered. Refer to => [ Important! Clutch cover location ] Multi-Plate Clutch, Preparing for Installation.
1 Multi-Plate Clutch/Clutch Housing
2 Oil Seal
• Quantity: 4
3 Large Lamella Carrier
• Do not remove.
CAUTION!
Avoid removing or lifting the Lamella carrier even slightly! The clutch discs could rotate.
4 Outer Disc
• Quantity: 4
5 Inner Clutch Disc
• Quantity: 4
6 Thrust Washer
7 Circlip
• In the event the circlip was removed in order to reinsert discs, it should be replaced with a new circlip of the same thickness.
8 Circlip
• This circlip must be resized with each clutch installation
9 Clutch Cover
10 Circlip
• Always replace
• Do not install any wavy circlips.