Clutch, Installing and Adjusting

Clutch, Installing and Adjusting

CAUTION!
Avoid removing or lifting up the clutch pack carrier. Not even slightly! The clutch discs could rotate themselves.

• Transmission must be turned vertically in assembly bracket. This is the only position in which the clutch axial play can later be adjusted without complications.

- The transmission must be secured tightly in holding fixture (VW 313) or Engine and Transmission Holder (VAS 6095) --> [ Transmission, Transporting and Securing to Assembly Bracket ] Transmission, Transporting and Securing to Assembly Bracket. It must not be turned.

- In the clutch, the large clutch pack carrier is inserted into all clutch discs, and must not be slip out of bottom clutch disc.

- Oil pump shaft is removed.

Special tools, testers and auxiliary items required

• Retaining Bar (T10303)

- First place - retaining bar - on cover seat.





- Install- clutch -, do not let it fall in.





- - Retaining bar - should be held in place by a second technician when doing this.





- Retaining bar - remains there until clutch end cover is installed.

- Determine securing ring with 2 mm thickness- arrow - from all securing rings supplied and install it temporarily.





Before this ring is removed again, two measurements must be performed first.

First measurement

• Retaining Bar (T10303) remains installed!

- Install Dial Gauge Holder (VW387) on to transmission flange.

- Place - dial gauge - on input shaft.





- Adjust - dial gauge - preload to 0.

- Lift clutch upward until it stops and note measurement result.

Second measurement

• Retaining Bar (T10303) remains installed!

- Place dial gauge plunger on hub on large clutch pack carrier.





• Plunger must not rest on securing ring.

- Readjust - dial gauge - preload 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 securing rings will be finally installed:

- To do this, use this formula

Second measurement minus first measurement plus 1.85 mm = thickness of securing ring to be installed

- Note this result.

The remaining nine securing rings are staggered in 0.1 mm increments.

- Measure all rings and then determine the ring which matches your result.

- Remove 2 millimeter thick ring and replace with the determined ring.

- Dispose of remaining rings and 2 mm ring.

Securing rings must only be installed one time.

- Insert - pump shaft -.





- Insert clutch cover so that tab aligns with mark.





- Place new securing ring in clutch.

- Note writing - TOP -.

TOP must always be visible (face upward)!

- Remove Retaining Bar (T10303).





- Install cover (end cover) --> [ Clutch End Cover, Installing ] Clutch End Cover, Installing

This concludes installation, the clutch is correctly adjusted.

After installing transmission

- Perform basic measurement on Direct Shift Gearbox (DSG) Mechatronic (J743).

Special care

All components have been balanced with each other by 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 --> [ Important! Clutch cover location. ] Multi-Disc Clutch, Installing