Volkswagen Golf Variant / Jetta. Manual - part 549

 

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Volkswagen Golf Variant / Jetta. Manual - part 549

 

 

❑ Removing. Refer to

⇒ “1.2 Dual Clutch, Removing, through Transmission Production Date 05/2011”, page 17

 .

❑ Installing. Refer to

⇒ “1.4 Dual Clutch, Installing, Transmission Production Date through 05/2011”, page 33

 .

1.2

Dual Clutch, Removing, through Trans‐

mission Production Date 05/2011

Special tools and workshop equipment required
♦ T-Handle Hook - 3438-
♦ Support Bridge - T10323-
♦ -T10356/5- from the Subframe Bushing Assembly Tool Kit -

T10356-

♦ Puller - Clutch - T10373-
♦ Clutch Press Piece - T10376-
♦ Engine Bung Set - VAS6122-
– Remove the transmission:
♦ Refer to

⇒ “4 Transmission, Removing and Installing, Jetta from MY

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

2010”, page 127

♦ Refer to

⇒ “5 Transmission, Removing and Installing, Jetta from MY

2011”, page 166

• The DSG Transmission Mechatronic - J743- is installed in the

transmission.

– Remove both caps -arrows- and seal with suitable oil-tight

plugs from the Engine Bung Set - VAS6122- for example.

Caution

On some transmissions, the breather cap on the Mechatronic

is destroyed during removal and must be replaced.
Checking the hydraulic fluid level for the Mechatronic is not

possible. The Mechatronic vent must be sealed oil-tight before

performing any assembly work.
Fluid that has leaked out of the Mechatronic hydraulic area may

not be refilled or checked. Replace the Mechatronic if fluid is

leaking.

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

17

clutch facing up.
Refer to

⇒ “6 Transmission, Transporting and Securing To Assembly

Stand”, page 191

 for information on securely transporting the

transmission and securing to the assembly stand.

Note

The dual clutch is removed upward. The Mechatronic stays on

the transmission.

– Remove the locking ring -arrow- from the hub.

– Remove the hub using T-Handle Hook - 3438- and a screw‐

driver.

– Remove the locking ring -arrow- from the clutch.
If it is Not Possible to Remove the Locking Ring:

Note

The clutch is »jamming« the circlip from underneath if the cir‐

clip cannot be removed.

If this is the case, then push the clutch slightly down and this

will release the pressure on the locking ring. Never hit the

clutch or the shaft with a hammer.

Always replace the locking ring.

18

sion flange, as illustrated.

– If necessary, even out the gaps with Assembly Tool - 5 -

T10356A/5- for example.

– Tighten the bolts -A- hand-tight.

Note

Secure the bolts -A- with a nut, if needed.

Caution

Danger of damaging the clutch and other components.

• Push the clutch down gently without pressing.

– Turn the spindle against the Clutch Press Piece - T10376- to

lower it.

– Remove the special tool and remove the circlip -arrow- for the

clutch.

Continuation for Removing the Locking Ring:
– Insert the Puller - Clutch - T10373- into the clutch and remove

the clutch.

– Remove the clutch together with the Puller - Clutch - T10373- .

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

19

– Remove the bolts and remove the engaging lever with the

bracket.

Note

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

– Remove the engaging lever mount.
Before installing the clutch, check if the »clutch needs to be ad‐

justed or not during assembly«. Refer to

⇒ “1.3  K 1 and K 2 Clutch Engaging Bearing Position, Adjusting,

Transmission Production Date through 05/2011”, page 20

 .

Adjusting. Refer to

⇒ “1.3  K 1 and K 2 Clutch Engaging Bearing Position, Adjusting,

Transmission Production Date through 05/2011”, page 20

Install the Dual Clutch. Refer to

⇒ “1.4 Dual Clutch, Installing, Transmission Production Date

through 05/2011”, page 33

 .

1.3

“K 1” and “K 2” Clutch Engaging Bearing

Position, Adjusting, Transmission Pro‐

duction Date through 05/2011

Special tools and workshop equipment required
♦ Setting Tool - Release Bearing - T10374-
♦ Ruler (2 pc.) - T40100-
♦ Digital Depth Gauge - 300mm for example -VAS6594-
♦ Adhesive - AMV 195 KD1 01-
♦ Micrometer

20

 

 

 

 

 

 

 

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