Volkswagen Golf Service & Repair Manual: Installing dual clutch

Special tools and workshop equipment required

Support device -T10323-

-T10356/5- from assembly tool -T10356-

Puller -T10373-

Thrust piece -T10376-

Installing

Caution

Risk of damage to clutch and other components!

The positions of the engagement bearings must be set correctly.

Adjustment can only be carried out before the clutch is installed.

The position of the engagement bearings must be adjusted after the following tasks:

Clutch has been renewed.

Engaging levers were renewed.

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

Engagement bearings were renewed.

If you have performed any of the above work, you must now adjust the position of engagement bearings “K 1 and K 2” → Chapter.

Only when the adjustment is correct may assembly work be continued.

If no new parts have been installed, insert removed shims.

Only one shim per engagement bearing may be installed.

Clutch parts must be free of oil and grease.

Risk of damage from clutch adjustment device.

The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Do not allow clutch to fall into gearbox during installation.

Requirement:

Clutch engagement mechanism installed → Chapter.

Turn back spindle of puller -T10373-.

Install clutch with puller -T10373- in gearbox, as shown in diagram.

Position support bracket -T10323- parallel to gearbox flange as shown in illustration.
If necessary, balance out gaps using -T10356/5- from assembly tool -T10356-, for example.
Screw in bolts -A- hand-tight.

Note

Bolts -A-, secure with nut as required.

Press on clutch as far as it will go.

Note Place a hand on clutch whilst pressing on. A slight »rattling« will be felt. Rattling indicates that the clutch is being pressed onto its press seat. This also enables detection of the limit stop once the clutch has been seated correctly.

Take hold of new retaining ring with retaining ring pliers, as shown in the illustration.

Installation position: narrow surface of retaining ring on top.

Inserting retaining ring -arrow-.

Note If the retaining ring cannot be inserted, the clutch has not been pressed in onto its limit stop.

To ensure that the clutch reaches its operating position right from this stage, turn it against puller -T10373--arrow- by hand without using any other tools.

Note By pressing on, the clutch sits at the bottom against the limit stop on the input shaft. This is not the optimum position.

Clutch should only be pulled up far enough for it to contact retaining ring.

Only turn by hand. In this way, clutch slides against retaining ring. Do not use any other tool.

Insert hub.

Hub has »large tooth«-arrow- and only fits in one position.

»Large tooth« has a mark at engine end.

Insert retaining ring -arrow- of hub.

Joint of retaining ring must point towards »hub« of clutch.

Turn clutch by hand. It should be possible to turn it without difficulty.

Note If the clutch is difficult to turn or if the clutch lining is being rubbed hard, remove clutch again → Chapter.

Check installation position of shims -arrows-.

The shims must be properly seated and must not be damaged.

A mathematical error could have been made. Check measurements again → Chapter

If no fault can be found, the clutch may have been moved out of position due to transport/assembly and a new clutch now has to be installed. The position of the engagement bearings must then be readjusted → Chapter.

Remove two plugs and put breather caps -arrows-on.

Note The breather cap on the mechatronic unit is destroyed during removal and must be renewed.

Dispose of excess shims.
After installing the gearbox, use the vehicle diagnostic tester to run the Basic setting complete function in Guided Functions.

Installing dual clutch