Volkswagen Golf Variant / Jetta. Manual - part 320

 

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Volkswagen Golf Variant / Jetta. Manual - part 320

 

 

tioned between the color-marked teeth of the outer clutch plate

carrier.

If no marking is available:
– Mark the location of the tab to the outer clutch plate carrier

circumference with a waterproof marker as shown.

• When installing, the drive plate tab must be placed back on

this marked location.

– Insert the Clutch Retaining Bar - T10303- in the position on the

clutch end cover as shown.

– Set the dual clutch using rotating and lifting movements into

the clutch housing, but do not let it fall in. Press the drive plate

into the outer clutch pack carrier with both thumbs in direction

of -arrows- to install.

Do not install on clutch. The clutch is inserted with the cover as it

was in the packaging.

• A second technician should hold the Clutch Retaining Bar -

T10303- .

Note

The retaining pin remains there until clutch end cover is in‐

stalled.

The dual clutch must not be turned any more now, otherwise

the Clutch Retaining Bar - T10303- could be twisted in its po‐

sition.

2. Dual Clutch, Removing and Installing    

27

driver -1- in direction of -arrow-.

Caution

Do not remove or lift the inner clutch plate carrier, under any

circumstances. The clutch plates could rotate themselves.

– Remove the drive plate from the installed clutch in direction of

-arrows-, if necessary, use a screwdriver to carefully pry it out

of the teeth of the outer clutch plate carrier.

– Move the drive plate to the side.

Identifying the Circlip for the Dual Clutch.
– Select the 2 mm thick ring from the circlips delivered and install

it -arrow-.

Note

For the initial measurement, temporarily insert 2 mm thick circlip.

After the measurement has been determined, replace it with the

final circlip.

First Measurement
• The Clutch Retaining Bar - T10303- remains installed.
– Install the Dial Gauge Holder - VW387- on the transmission

flange.

28

urement result.

Second Measurement
• The Clutch Retaining Bar - T10303- remains installed.

– Place the dial gauge test probe on the

-inner clutch plate carrier hub-.

Note

Do not place the dial gauge test probe on the circlip.

– Set the -dial gauge- to “0” again with 2 mm pretension.
– Raise the dual clutch up as far as the stop again and note this

measurement as well

Now the Calculation Will Be Made to Determine Which of the Re‐

maining Nine Circlips Will Be Finally Installed:
– Use this formula:

2nd measurment value - 1st measurment value + 1.85 mm =

circlip thickness

– Note the result.
The remaining nine circlips are staggered in 0.1 mm increments.
– Measure all the circlips and determine the one that is the clos‐

est match to the result.

Determined Measurement for

the New Circlip

New Circlip

2.27 mm

2.3 mm

2.24 mm

2.2 mm

Note

If the measurement determined for the new circlip is 2 mm, the

circlip that was inserted temporarily remains installed.

2. Dual Clutch, Removing and Installing    

29

measured.

– Dispose of all other remaining circlips and the 2 millimeter thick

circlip.

Note

Circlips must only be installed one time.

– Insert the pump shaft by lifting the pump shaft and turning it

slightly -arrow- so that it slides all the way into the splines.

– Insert the drive plate into the dual clutch.
• The protruding tab on the drive plate -arrow- must be installed

between the marked teeth or the marking applied to the outer

clutch plate carrier.

– Install the »new« drive plate circlip.
• The circlip must be installed so that the tab of the drive plate

and the color-marked teeth of the outer clutch pack carrier are

positioned between both ends of the circlip.

• The circlip must be completely engaged.
– Check the exact installation position of the circlip and that the

circlip is engaged using a screwdriver.

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