Clutch, Installing and Adjusting
Clutch, Installing and Adjusting
Avoid removing or lifting up the clutch pack carrier. Not even a little! The clutch discs could rotate themselves.
Requirements:
• Transmission must be turned vertically in the transmission holder. 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 ] Transmission, Transporting and Securing To Assembly Stand. Do not turn it.
• The large lamella carrier is inserted in all clutch discs in the clutch. The large lamella carrier must not slip out of the lowest clutch disc.
• The oil pump shaft is removed.
• Do not install any wavy circlips.
Installing
Special tools, testers and auxiliary items required
• Retaining Bar (T10303)
- First, place the retaining bar on the cover seat.
- Then, insert the clutch, do not let it fall in.
Do not install the clutch on the retaining bar. The clutch is inserted with the cover as it was in the packaging.
- A second technician should hold the retaining bar.
The retaining bar remains installed until all other work is completed.
Only remove the bar hen instructed to do so. Not right now.
- Remove the cover - arrow - from the clutch and move it to the side.
Avoid removing or lifting up the clutch pack carrier. Not even a little! The clutch discs could rotate themselves.
- Select the 2 mm circlip - arrow - provided with all the circlips and carefully install it.
Perform two measurements before removing the circlip again.
First Measurement:
• The retaining bar (T10303) remains installed.
- Install the dial gauge holder (VW 387) on 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 dial gauge button on the hub of the large clutch pack carrier.
The plunger must not rest 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 finally installed:
- Use this formula:
Second measurement minus the first measurement plus 1.85 mm = the thickness of the circlip to be installed
- Note the result.
The remaining 9 circlips are sized 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 circlips remaining and the 2 millimeter circlip.
The circlips must only be installed one time.
- Insert the pump shaft.
- Insert the clutch cover so that tab aligns with the mark.
- Remove the retaining bar (T10303).
- Install the cover (end cover). Refer to => [ Clutch Cover, Installing ] Clutch Cover, Installing.
When the installation is completed, the clutch is adjusted correctly.
After installing the transmission
- Perform a basic measurement on the DSG transmission Mechatronic (J743).
Special Care
Installing the multi-plate clutch requires special care because: All components were balanced to 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 the 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 Seal
• Quantity: 4
3 Large Clutch Pack
• Do not remove
Avoid removing or lifting up the clutch pack carrier. Not even a little! The clutch discs could rotate themselves.
4 Outer Clutch Disc
• Quantity: 4
5 Clutch Disc
• Quantity: 4
6 Thrust Washer
7 Circlip
• If the circlip was removed in order to install the discs, it should be replaced with a new circlip of the same thickness.
8 Circlip
• This circlip must be re-sized with each clutch installation.
9 Clutch Cover
10 Circlip
• Always replace.
• Do not install any wavy circlips.