Volkswagen Golf Variant / Jetta. Manual - part 553

 

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Volkswagen Golf Variant / Jetta. Manual - part 553

 

 

Dual Clutch, Installing, Transmission

Production Date through 05/2011

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

T10356-

♦ Puller - Clutch - T10373-
♦ Clutch Press Piece - T10376-
♦ Adhesive - AMV 195 KD1 01-
• Tightening specifications. Refer to

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

tion Date 05/2011”, page 15

 .

Caution

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.

Refer 

to

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

ing,  Transmission  Production  Date  through  05/2011”,

page 20

 .

Note

Clutch components must have no oil or grease on them when

being installed.

Replace all bolts that were tightened with an additional turn.

The following four steps are only necessary if the engaging

bearing position did not need to be adjusted.

– Insert the engaging lever mount.

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

33

Note

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

– Tighten the small engaging lever with two new bolts.

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

Caution

Danger of damaging the dual clutch and other components.

• The position of the engaging bearings must be adjusted

correctly.

Adjusting the engaging bearings can only be performed prior

to installing the dual clutch.
The position of the engaging bearing must be adjusted after

completing the following:

♦ The dual clutch was replaced.
♦ The engaging levers were replaced.
♦ The engaging lever mount was replaced.
♦ The engaging bearings were replaced.

It is necessary to adjust the position of the “K 1 and K 2” en‐

gaging bearings first if one of the above mentioned procedures

was performed and the readjusted shim is inserted. Refer to

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

ing,  Transmission  Production  Date  through  05/2011”,

page 20

 .

Continue with assembling only when the adjustment is correct.
The removed shims can be used again if no new parts were

installed.
Only one shim per engaging bearing can be inserted for the

adjustment.

34

-2- for the “K 2” clutch.

The Shim Belongs Under the Small Engaging Bearing. Install the

Shim First.

• 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.

– Secure the »large« shim -1- for the “K 1” clutch with three

drops of Adhesive - AMV 195 KD1 01- -arrows-.

This prevents the shim from sliding out of its position when in‐

serting the clutch.

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

35

Caution

Danger of causing damage to the clutch adjusting tool.

♦ The clutch is self-adjusting. Vibrations can affect the ad‐

justing tool. Be careful not to drop the clutch into the

transmission when installing.

– Install the clutch in the transmission using the Puller - Clutch

- T10373- as shown.

– Position the Support Bridge - T1032- parallel to the transmis‐

sion flange, as illustrated.

– If necessary, even out the gaps using, for example, -T10356/5-

from the Assembly Tool - T10356A- .

– Tighten the bolts -A- hand-tight.

Note

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

– Install the clutch all the way.

Note

Keep on hand on the clutch while pressing it on. A slight »vibrat‐

ing« can be felt. Vibrating means the clutch is being pushed onto

its press-fit. It can also be felt when the clutch has reached its

stop.

– Hold the new locking ring with locking ring pliers, as illustrated.
• Installed position: narrow ends of the locking ring at the top.

– Install the circlip -arrow-

Note

The clutch is not pressed correctly on the stop if the locking ring

cannot be installed.

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