Volkswagen Golf Variant / Jetta. Manual - part 552

 

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Volkswagen Golf Variant / Jetta. Manual - part 552

 

 

Bearing

– Only insert the small engaging bearing.

• The small engaging bearing fits in only one position due to the

4 grooves.

– Turn the engaging bearing in direction of -arrows- to make

sure it is installed correctly and fits correctly in the grooves.

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

29

large opening upward on the small engaging bearing.

– 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.

• The Ruler (2 pc.) - T40100- lies straight across the transmis‐

sion flange over the end of the shaft.

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.

– Set the Depth Gauge to “0”.

– Position the depth gauge on the Setting Tool - Release Bear‐

ing - T10374- as shown.

– Measure dimension “A 2a ” at this position on the Setting Tool

- Release Bearing - T10374- .

• Example: dimension “A 2a ” = 2.50 mm

30

Setting Tool - Release Bearing - T10374- .

• Example: dimension “A 2b ” = 2.54 mm
– Calculate the average value from dimension “A 2a ” and “A

2b ”.
Formula: A 2a + A 2b 2

Example:
• 2.50 + 2.542 = 2.52 mm
• Result: dimension “A 2” = 2.52 mm
Step 9: Measure the Installation Depth for the “K 2” Clutch En‐

gaging Bearing.

Note

Based on dimension “A 2” and dimension “B”, calculate the actual

value for the “K 2” clutch engaging bearing as follows:

 

Dimension “A 2”

Dimension “B”

+

Inner Setting Tool - Release Bearing - T10374- dimension

(36.20 mm; fixed value)

=

Actual value of the “K 2” clutch engaging bearing installa‐

tion depth

Example:
• 2.52 mm – 2.96 mm + 36.20 mm = 35.76 mm
• Result: Actual value for “K 2” clutch engaging bearing instal‐

lation depth = 35.76 mm

Step 10: Measure the Air Gap for “K 2” Clutch.

Note

Based on the actual value and the specified value of the installa‐

tion depth for the engaging bearing, the air gap for the “K 2” clutch

is measured as follows:

 

Engaging bearing installation depth actual value

Specified value for engaging bearing installation depth

(34.35 mm; fixed value)

=

Air gap for “K 2” clutch

Example:
• 35.76 mm – 34.35 mm = 1.41 mm
• Result: Air gap for “K 2” clutch = 1.41 mm

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

31

illustrated.

Step 12: Measure the “SK 2” Shim Thickness.

Note

Based on the air gap and the clutch tolerance for the “K 2” clutch,

now the “SK 2” shim thickness can be calculated as follows:

 

Air gap for “K 2” clutch

–/+ Clutch tolerance for the clutch “K 2”
=

Calculated thickness for shim “SK 2”

Example:
• 1.41 mm – 0.20 mm = 1.21 mm
• Result: calculated “SK 2” shim thickness = 1.21 mm

– Measure the needed shim from the shims supplied and keep

it close for installation.

Calculated Shim Thickness

mm

Available Shim

Thicknesses in mm

0.31 to 0.90

0.80

0.91 to 1.10

1.00

1.11 to 1.30

1.20

1.31 to 1.50

1.40

1.51 to 1.70

1.60

1.71 to 1.90

1.80

1.91 to 2.10

2.00

2.11 to 2.30

2.20

2.31 to 2.50

2.40

2.51 to 2.70

2.60

2.71 to 3.30

2.80

Example:
• Result: calculated “SK 2” shim thickness = 1.21 mm
• Selected shim thickness = 1.20 mm

Caution

Risk of damaging the transmission.

♦ Mark the shim with “SK 2” and keep it ready for assembly.
♦ Only this “SK 2” shim may be inserted for an adjustment.

– Install the dual clutch. Refer to

⇒ “1.4 Dual Clutch, Installing, Transmission Production Date

through 05/2011”, page 33

 .

32

 

 

 

 

 

 

 

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