Volkswagen Golf Variant / Jetta. Manual - part 317

1

Overview - Dual Clutch

Dual Clutch General Information

The term »clutch« is not completely accurate on closer examina‐

tion. DSG® clutches always contain at least two »clutches« which

is why the term “dual clutch” is more appropriate. In this case, the

clutch has two clutch disc packs - that is, a wet clutch. The outer,

larger clutch plate pack is called “K 1” (clutch 1). The “K 1” shifts

reverse gear and »1st«, »3rd« and »5th« gears. The inner, small‐

er “K 2” (clutch 2) shifts the gears »2«, »4« and »6«.
Assembling the dual clutch requires special care, because all of

the components were balanced to each other at the manufacturer.

When positioning components during installation, do not rotate

out of their original position, otherwise imbalances will occur, cre‐

ating diminished shift comfort and life span.
Replacement clutches are supplied with the circlip already instal‐

led.
To avoid the risk of turning parts from one another in the first

place, it is shown here how the clutch is assembled in the trans‐

mission housing and installed. Follow the descriptions exactly.

Refer to 

⇒ “2 Dual Clutch, Removing and Installing”, page 18

 .

Replacement Part Package

1. Overview - Dual Clutch    

15

Caution

♦

The drive plate (upper

section of the dual clutch)

of a new clutch is not se‐

cured with the circlip, it

only sits »taut« in the

clutch.

♦

The drive plate must re‐

main engaged between

the teeth of the outer

clutch plate carrier.

♦

If the drive plate is loos‐

ened, the plates in the

dual clutch can slip out of

place and it cannot be ad‐

justed correctly during in‐

stallation under the cir‐

cumstances.

2 - Circlip

❑ Quantity: 10, with vari‐

ous thicknesses for ad‐

justment

❑ When installing the dual

clutch, the thickness of

the circlip must be de‐

termined. Refer to

⇒ page 28

3 - Clutch End Cover
4 - Clutch End Cover Circlip

Individual Components of Disassembled Dual Clutch

Caution

16

ing

❑ Outer clutch plate carri‐

er

2 - Seal

❑ Quantity: 4

3 - Inner Clutch Plate Carrier

❑ Do not remove

Caution

Do not lift or remove the

inner clutch plate carrier

under  any  circumstan‐

ces.  The  clutch  plates

could rotate themselves.

4 - Outer Clutch Plate

❑ Quantity: 4

5 - Inner Clutch Plate

❑ Quantity: 4

6 - Thrust Washer
7 - Circlip

❑ If the circlip was re‐

moved in order to rein‐

sert the plates, it should

be replaced with a new

ring of the same thick‐

ness.

8 - Circlip

❑ After installing a new du‐

al clutch, redetermine

the thickness. Refer to

⇒ page 28

 .

9 - Drive Plate
10 - Circlip

❑ Replace after removing
❑ Do not install any wavy circlips

1. Overview - Dual Clutch    

17

Dual Clutch, Removing and Installing

⇒ “2.1 Remove Clutch End Cover”, page 18
⇒ “2.2 Clutch End Cover, Installing”, page 20
⇒ “2.3 Dual Clutch, Removing”, page 24
⇒ “2.4 Dual Clutch, Installing and Adjusting”, page 25

Before the dual clutch can be removed, remove the clutch end

cover from the dual clutch. Refer to

⇒ “2.1 Remove Clutch End Cover”, page 18

 .

2.1

Remove Clutch End Cover

Brief Description
The clutch cover closes the transmission toward the outside. A

circlip holds the clutch end cover in place. Remove the circlip and

pry out the clutch end cover. Always replace the clutch end cover

and the locking ring. Never use a hammer to install the clutch

cover and never lubricate the center seal or touch it. If this should

occur, the clutch cover will certainly leak!
The transmission must be removed in order to work on the cover.
– Remove the transmission. Refer to

⇒ “6 Transmission, Removing and Installing, Jetta from MY

2005 , Golf Wagon from MY 2007 and Golf Wagon from MY

2010”, page 88

 or

⇒ “7 Transmission, Removing and Installing, Jetta from MY

2011”, page 102

 .

– Secure the transmission on the assembly stand. Refer to

⇒ “8 Transmission, Transporting and Securing to Assembly

Stand”, page 131

 .

– Place a Drip Tray under the transmission.

– Drain the fluid.
Through transmission production date “09/20/2004”, transmis‐

sions were installed with two plugs.
Then the second plug was discontinued so that draining oil and

adjusting the oil level can both be done using plug -A-.
A plastic overflow tube is located in this hole (with 8 mm hex

socket head, tightening specification: 3 Nm). Its length deter‐

mines the fluid level in the transmission.
– Remove this overflow pipe and drain the remaining transmis‐

sion fluid.

Note

Approximately 5 liters (5.28 qts) of transmission fluid will flow out.

Leave the Drip Tray under the transmission.

– Install the overflow pipe and tighten it to 3 Nm.

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