Clutch, Installing and Adjusting

Clutch, Installing and Adjusting

• The drive plate of a new clutch is not secured with the lock ring, 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 the clutch can slip out of place. The clutch may not be correctly set during installation under certain circumstances.

- Take the clutch out of the packaging by pressing the drive plate into the outer clutch pack carrier with both thumbs.






- Next, secure the drive plate in the externally toothed plate carrier with the "old" lock ring - A - from the removed clutch.






• Do not use the new lock ring that was delivered with the package.

• The lock ring 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 lock ring.

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






• The ends of the seals should not overlap one another.

- Turn the seals one time. They must move freely and must not stick.

Important! Installed position of the drive plate





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

If no mark 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.

- Place the retaining bar (T10303) in position on the clutch cover as shown in the illustration.






- Set the clutch using a rotating motion into the clutch housing, but do not let it fall in. Press the drive plate into the outer clutch pack carrier with both thumbs - arrows - to install.






• A second technician should hold the retaining bar (T10303).






• The retaining bar remains there until the clutch end cover is installed.

• The clutch must not be turned any more, otherwise the retaining bar (T10303) could be twisted in its position.

- Remove - arrow - and dispose of the old lock ring - 2 - using a screwdriver - 1 -.






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 - arrows -, if necessary, use a screwdriver to carefully pry it out of the teeth of the outer clutch pack carrier.






- Move the drive plate to the side.

Identify the circlip for the clutch






- Select the 2 mm thick circlip from the circlips delivered and install it - arrow -.

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

First Measurement:

• The retaining bar (T10303) remains installed.

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

- Place the dial gauge button on the input shaft.






- Adjust the dial gauge pretension to 0.

- Raise the clutch up as far as the stop and note the measurement

Second Measurement:

• The retaining bar (T10303) remains installed.

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






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

- Readjust the dial gauge pretension to 0.

- Raise the clutch up as far as the stop again and note this measurement as well

Now the calculation will be made to determine which of the remaining nine circlips will be installed:

- Use this formula:

2nd measured value - 1st measured value + 1.85 mm = Circlip thickness

- Write down the result.

The remaining nine circlips are staggered in 0.1 mm increments.

- Measure all the circlips and determine the one that is the closest match to the result






- Remove the 2 mm circlip and replace it with the circlip that was measured.






- Dispose of all the other remaining circlips and the 2 millimeter circlip.

• Circlips must only be installed one time.

- Insert the 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 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 the marks that have been changed retrospectively.

- Install the new drive plate lock ring.






• The lock ring 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 lock ring.

• The lock ring must be completely engaged.

- Check the exact installed position of the lock ring and that the lock ring is engaged using a screwdriver.

- Now remove the retaining bar (T10303) from between the clutch and the housing.

- Install the clutch end cover. Refer to => [ Clutch End Cover, Installing ] Clutch End Cover, Installing.