Volkswagen Golf Variant / Jetta. Manual - part 550

The following components must also be replaced if the dual

clutch is replaced:

♦ Both engaging levers with engaging bearing.
♦ Engaging lever mount.
♦ Engaging bearing shims.

When replacing the dual clutch and its components, the “K 1

and K 2” engaging bearing position must always be readjusted.

Note

♦

It is not necessary to perform an adjustment if all the men‐

tioned components are only removed and reinstalled.

♦

The locking ring must be replaced in each case.

Brief Description
♦ The position of the engaging bearing is comparable to clutch

play on a manual transmission. There are tolerances in the 7-

speed DSG® transmission 0AM engaging system and in the

transmission itself. There are also tolerances within the dual

clutch. These tolerances must be taken into account sepa‐

rately when performing the adjustments.

♦ The following procedure describes how all necessary meas‐

urements are determined from the transmission side in order

to select the correct shim. In addition to this, the tolerances in

the clutch already determined by the manufacturer. The trans‐

mission side tolerances and the tolerances in the clutch de‐

termine the thickness of the shim.

♦ Follow the work sequence.
Overview - Clutch Mechanism

1. Dual Clutch, Removing and Installing, through Transmission Production Date 05/2011    

21

»K 2«

❑ Always replace when

replacing the dual clutch

2 - Shim for »K 2«
3 - Engaging Bearing for »K 2«

❑ Always replace when

replacing the dual clutch

4 - Large Engaging Lever for

“K 1”

❑ With large engaging

bearing

❑ Always replace when

replacing the dual clutch

5 - Shim for “K 1”
6 - Bolts

❑ 8 Nm +90°
❑ Always replace after re‐

moving

7 - Bracket

❑ Not equipped in some

older transmissions

❑ Always replace when

replacing the dual clutch

8 - Support

❑ Always replace when

replacing the dual clutch

Requirement:
• The transmission flange must be even so that it has a good

surface for the ruler.

• DSG Transmission Mechatronic - J743- must be installed.
• Tightening specifications. Refer to

⇒ “1.1 Overview - Dual Clutch, through Transmission Produc‐

tion Date 05/2011”, page 15

 .

Note

Replace any bolts that were tightened with an additional turn.

Caution

Danger of damaging the clutch and other components.

• The mount for the engaging lever and the entire mechan‐

ical system for the engaging bearing must be dry and free

from oil and grease.

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– Install the small engaging lever with the bracket and tighten

with two new screws.

Note

Only a few »older« transmissions do not have a bracket.

– Install the large engaging lever.
– Make sure both engaging levers fit correctly.

– Install the old circlip -arrow- for the outer input shaft.

1. Dual Clutch, Removing and Installing, through Transmission Production Date 05/2011    

23

– Place Ruler (2 pc.) - T40100- across the end of the shaft on

the transmission flange.

Caution

There is the risk of incorrect measurements.

♦ The Ruler (2 pc.) - T40100- should stay in this position for

the following measurements. Do not move it or take if off.

– Place the Digital Depth Gauge - 300mm - VAS6594- on top of

the Ruler (2 pc.) - T40100- and position the depth slide on the

outer input shaft.

– Set the Depth Gauge to “0”.

– Position the depth slide on the locking ring, as illustrated.
– Measure dimension “B1 ” on the locking ring in this position.
• Example: dimension “B1 ” = 2.92 mm

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