Volkswagen Golf Service & Repair Manual: Adjusting clutch engagement

The position of the engagement bearings “K 1” and “K 2” must only be adjusted after the following work:

Clutch has been renewed.

Engaging levers were renewed.

Small ball pin for engaging lever “K 2” has been renewed.

Engagement bearings were renewed.

Note There is no need to adjust anything if all the named parts have only been removed and reinstalled.

The retaining ring must be renewed in each case.

Special tools and workshop equipment required

Gauge block -T10466-

Ruler -T40100-

Not shown: Depth gauge, digital 300 mm -VAS 6594-

Conditions

Dual clutch removed → Chapter.

The gearbox flange must be level to assure good contact with the ruler.

Mechatronic unit for dual clutch gearbox -J743- built into gearbox.

Caution

Risk of damage to clutch and other components!

Mounting for engaging lever and entire mechanism of engagement bearing must be dry and free of oil or grease.

Removing and installing ball pin

Use pliers to remove ball-head pin.

Push in »new« ball pin by hand, if necessary using a plastic hammer and drift to tap it in.

Note To avoid damage to ball pin, only tap the drift lightly with the plastic head hammer.

Continuation for all:

Note If dimension “B” has already been determined, it is now possible to proceed with step “2” of the measurement → Anchor

Install previously used retaining ring -arrow- of outer input shaft.

1st step: Determine dimension “B” for clutch “K 1” and “K 2”

Place ruler -T40100- upwards across end of shaft onto gearbox flange.

Caution

Risk of false measurements.

The ruler -T40100- should remain in this position for the following measurements. Do not turn over, do not remove.

Fit digital 300 mm depth gauge -VAS 6594- on top of ruler -T40100-. Position depth gauge rod on outer input shaft.
Set depth gauge to “0”.

Position depth gauge rod on retaining ring, as show in diagram.
In this position, determine dimension “B₁” to retaining ring.

Example: dimension “B 1 ” = 2.62 mm

In the opposite position, determine dimension “B₂” to retaining ring.

Note Do not measure on retaining ring joint. The retaining ring could be pushed away and falsify the reading.

Example: dimension “B 2 ” = 2.58 mm

Calculate mean value from dimension “B₁” and “B₂”.

Formula:

B₁ + B₂

Example:

2.62 + 2.58

= 2.60 mm

Result: Dimension “B” = 2.60 mm

Note If the dual clutch is still installed following this measurement, it must now be removed → Anchor.

Remove retaining ring -arrow- of outer input shaft and dispose.

Note

It is not permissible to reuse the retaining ring.

2nd step: Determine dimension “A 1” for clutch engagement bearing “K 1”

Insert large engaging lever.

Caution

Risk of false measurements.

Do not insert any shim!

Check that engaging lever is seated correctly.

Place end gauge -T10466- on large engagement bearing. Flat side faces upwards.
To ensure that end gauge -T10466- sits properly on engagement bearing, press down and turn end gauge.

Engagement bearing will turn with end gauge -T10466-.

Fit digital 300 mm depth gauge -VAS 6594- on top of ruler. Position depth gauge rod on outer input shaft.

Ruler -T40100- is lying upwards across end of shaft on gearbox flange.

Caution

Risk of false measurements.

The ruler -T40100- should remain in this position for the following measurements. Do not turn over, do not remove.

Set depth gauge to “0”.

Position depth gauge rod on end gauge -T10466-, as show in diagram.
In this position, determine dimension “A 1_a” to end gauge -T10466-.

Example: Dimension “A 1 a ” = 5.03 mm

In the opposite position, determine dimension “A 1_b” to end gauge -T10466-.

Example: Dimension “A 1 b ” = 5.01 mm

Calculate mean value from dimension “A 1_a” and “A 1_b”.

Formula:

A 1_a + A 1_b

Example:

5.03 + 5.01

= 5.02 mm

Result: Dimension “A 1” = 5.02 mm

3rd step: Calculate height tolerance of clutch engagement bearing “K 1”

Note On the basis of dimension “A 1” and dimension “B”, the height tolerance of the engagement bearing for clutch “K 1” is now calculated according to the following calculus.

	Dimension “A 1”
–	Dimension “B”
=	Actual height tolerance of clutch engagement bearing “K 1”

Example:

5.02 mm – 2.60 mm = 2.42 mm

Result: Height tolerance of clutch engagement bearing “K 1” = 2.42 mm

4th step: Determine clutch tolerance of clutch “K 1”

Read clutch tolerance value from new clutch.

Example: Read off clutch tolerance value on clutch “K 1 = +0.2”, as shown in diagram.

Result: Clutch tolerance of clutch “K 1” = + 0.20 mm.

5th step: Determine thickness of shim “SK 1”

Note On the basis of the clutch tolerance “K 1”, the thickness of shim “SK1” is now calculated according to the following calculus.

	Height tolerance of engagement bearing “K 1”
–/+	Clutch tolerance of clutch “K 1”
=	Calculated thickness of shim “SK 1”

Example:

2.42 mm + 0.20 mm = 2.62 mm

Result: Calculated thickness of shim “SK 1” = 2.62 mm

Select required shim from the table with the help of the part number -magnifying glass- and have it ready for installation.

Calculated thickness of shim mm	Available shims Thickness in mm	Part number of shim
1.21 … 1.60	1.50	0AM 141 383
1.61 … 1.80	1.70	0AM 141 383 A
1.81 … 2.00	1.90	0AM 141 383 B
2.01 … 2.20	2.10	0AM 141 383 C
2.21 … 2.40	2.30	0AM 141 383 D
2.41 … 2.60	2.50	0AM 141 383 E
2.61 … 2.80	2.70	0AM 141 383 F
2.81 … 3.00	2.90	0AM 141 383 G
3.01 … 3.20	3.10	0AM 141 383 H
3.21 … 3.40	3.30	0AM 141 383 J
3.41 … 3.80	3.50	0AM 141 383 K

Example:

Result: Calculated thickness of shim “SK 1” = 2.62 mm

Chosen shim thickness = 2.70 mm = part number 0AM 141 383 F

Caution

The clutch can be damaged.

Install only this shim later when required.

Remove end gauge -T10466- and large engagement lever again.

6th step: Determine dimension “A 2” for clutch engaging lever “K 2”

Note The upper section of bushing cannot be removed or installed alone. It is always removed or installed together with lower section of bushing and »small« engagement lever.

Observe the following when installing a new engaging lever »K2«:

The new engaging lever »K2« with upper and lower section of guide sleeve will be delivered in transport position -illustration- and must be set to installation position prior to installation.

Setting engaging lever »K2« to installation position:

Hold upper section of guide sleeve with one hand. With the other hand turn the lower section of guide sleeve in direction of arrow until the sleeve moves freely.

Note Apply high force to hold both sections, as this is necessary for turning the lower section of the guide sleeve.

If the engaging lever is in installation position, the holes of the lower section of guide sleeve are at right angles to the engaging lever. The sleeve moves freely.