Volkswagen Golf Variant / Jetta. Manual - part 556

 

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Volkswagen Golf Variant / Jetta. Manual - part 556

 

 

bearing.

Note

The guide sleeve upper section cannot be removed or installed

separately. It is always removed and installed together with the

guide sleeve lower section and the »small« engaging lever.

– Remove the bolts and the »small« engaging lever with the

guide sleeve upper and lower sections.

The ball stud -2- remains installed if no components are replaced.
The engaging lever support -1- is not removed.

Note

If dimension “B” was already measured, then step “2” of the

measurement can be made now. Refer to 

⇒ page 50

 .

2.3

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

Position, Adjusting, Transmission Pro‐

duction Date from 06/2011

Caution

The following components must also be replaced if the dual

clutch is replaced:

♦ Both engaging levers with engaging bearing.
♦ Ball stud for the “K 2” engaging lever.
♦ Engaging bearing shims.

When replacing the dual clutch and its components, the “K 1

and K 2” engaging bearing position must always be readjusted.

2. Dual Clutch, Removing and Installing, from Transmission Production Date 06/2011    

45

It is not necessary to perform an adjustment if all the compo‐

nents mentioned are only removed and reinstalled.

The locking ring must be replaced in each case.

Brief Description
♦ The position of the engaging bearing is comparable to clutch

play on a manual transmission. There are tolerances in the 7-

speed DSG® transmission 0AM engaging system and in the

transmission itself. There are also tolerances within the dual

clutch. These tolerances must be taken into account sepa‐

rately when performing the adjustments.

♦ The following procedure describes how all necessary meas‐

urements are determined from the transmission side in order

to select the correct shim. In addition to this, the tolerances in

the clutch already determined by the manufacturer. The trans‐

mission side tolerances and the tolerances in the clutch de‐

termine the thickness of the shim.

♦ Follow the work sequence.
Overview - Clutch Mechanism

1 - Shim for “K 1”

❑ Refer to

⇒ “2.3  K 1 and K 2

Clutch Engaging Bear‐

ing Position, Adjusting,

Transmission Produc‐

tion Date from 06/2011”,

page 45

2 - Large Engaging Lever for

“K 1”

❑ With engaging bearing
❑ Always replace when

replacing the dual clutch

3 - Engaging Lever Support

❑ For the large engaging

lever “K 1”

❑ Is not replaced

4 - Small Engaging Bearing for

“K 2”

❑ Always replace when

replacing the dual clutch

5 - Shim for “K 2”

❑ Refer to

⇒ “2.3  K 1 and K 2

Clutch Engaging Bear‐

ing Position, Adjusting,

Transmission Produc‐

tion Date from 06/2011”,

page 45

6 - Guide Sleeve Upper Sec‐

tion

❑ For the small engaging

lever “K 2”

46

together with the guide sleeve lower section

7 - Small Engaging Lever for “K 2”

❑ Is removed and installed together with the guide sleeve upper section and lower section
❑ Always replace when replacing the dual clutch

8 - Ball Stud

❑ For the small engaging lever “K 2”
❑ Always replace when replacing the dual clutch

9 - Bolts

❑ 8 Nm +90°
❑ Always replace after removing

10 - Guide Sleeve Lower Section

❑ For the small engaging lever “K 2”
❑ Removed and installed together with the guide sleeve upper section

Special tools and workshop equipment required
♦ Digital Depth Gauge - 300mm - VAS6594-
♦ Gauge - Clutch Bearings - T10466-
♦ Ruler (2 pc.) - T40100-
Requirement
• The transmission flange must be even so that it has a good

surface for the ruler.

• DSG Transmission Mechatronic - J743- must be installed.

Caution

Danger of damaging the clutch and other components.

• The mount for the engaging lever and the entire mechan‐

ical system for the engaging bearing must be dry and free

from oil and grease.

– Remove the ball stud installed using pliers.

2. Dual Clutch, Removing and Installing, from Transmission Production Date 06/2011    

47

drift gently, if necessary.

Note

Tap the drift gently with a hammer to avoid damaging the ball stud.

– Install the old circlip for the outer input shaft.

Step 1: Determine Dimension “B” for “K 1” and “K 2” Clutch.

– Place Ruler (2 pc.) - T40100- across the end of the shaft on

the transmission flange.

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.

48

 

 

 

 

 

 

 

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