Volkswagen Golf Variant / Jetta. Manual - part 319

 

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Volkswagen Golf Variant / Jetta. Manual - part 319

 

 

Clutch End Covers Delivered with Bush‐

ings, Installing

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.

Caution

Do not touch the hole in the center in a new clutch end cover.

The clutch end cover must not be touched inside the hole, oiled

or come into contact with any other substances in that area.

Leaks will develop.

Do Not Remove the Bushing!
The new clutch cover must not have any oil in the around the

center seal and it must be dry.
– Clean the end of the clutch shaft if necessary.
Do not apply any stickers to inside of the clutch end cover.
– If this is done, carefully remove the adhesive!
Only coat outer edge of seal with DSG® transmission fluid.

– Install the clutch end cover with bushing.

Caution

Handle with care. Any type of impact on the clutch end cover

will cause leaks.

The clutch end cover can be carefully lifted in its seat using a

screwdriver -arrow- until a »new« locking clip can be installed.
– Install the new circlip.

2. Dual Clutch, Removing and Installing    

23

2.3

Dual Clutch, Removing

To remove and install the dual clutch, the transmission must be

secured in a vertical position on the assembly stand.
– Remove the clutch end cover. Refer to

⇒ “2.1 Remove Clutch End Cover”, page 18

 .

– Pry out the drive plate circlip -2- with a screwdriver -1- in di‐

rection of -arrow-.

– Remove the drive plate in direction of -arrows-.

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ling.

Caution

Carefully remove the dual clutch. Make sure that no other parts

of the clutch fall out. Never turn over the clutch for this reason!

– Carefully remove the dual clutch from the transmission.

– Remove the pump shaft -A-.
– The pump shaft will be inserted first after the installation of the

new clutch. Set the shaft down until then.

2.4

Dual Clutch, Installing and Adjusting

Special tools and workshop equipment required
♦ Clutch Retaining Bar - T10303-

Caution

♦ The drive plate of a new clutch is not secured with a circlip,

it only sits “taut” in the clutch.

♦ Thus, press the drive plate into the outer clutch plate car‐

rier with both thumbs during the following steps.

♦ The drive plate must remain engaged between the teeth

of the outer clutch plate carrier.

♦ If the drive plate is loosened, the clutch plates in the dual

clutch can slip out of place. The dual clutch may not be

correctly set during installation under certain circumstan‐

ces.

2. Dual Clutch, Removing and Installing    

25

This is the only position in which the clutch axial play can later

be adjusted without malfunctions.

• Make sure the transmission is secure inside the Holding Fix‐

ture - VW313- or Engine And Transmission Holder -

VAS6095- . Refer to

⇒ “8 Transmission, Transporting and Securing to Assembly

Stand”, page 131

 . Do not turn it.

• The large lamella carrier is inserted in all clutch discs in the

clutch. The large lamella carrier must not slipped out of the

lowest clutch disc.

• Oil pump shaft is removed.
• Do not install any wavy circlips
– Take the dual clutch out of the packaging by pressing the drive

plate into the outer clutch plate carrier with both thumbs.

– Next, secure the drive plate in the outer clutch plate carrier

with the “old” circlip -A- from the removed clutch.

• Do not use the new circlip that was delivered with the package.
• The circlip must be installed so that the tab of the drive plate

-arrow- and the color-marked teeth of the outer clutch plate

carrier are positioned between both ends of the circlip.

– Check the bottom of the dual clutch to see if the four hub gas‐

kets are seated correctly and engage them in one another if

necessary.

• The ends of the rings should not stand over one another.
– Turn the rings one time. They must move freely and must not

stick.

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