Volkswagen Golf Variant / Jetta. Manual - part 557

 

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Volkswagen Golf Variant / Jetta. Manual - part 557

 

 

the Ruler (2 pc.) - T40100- and position the depth slide on the

outer input shaft.

– Set the depth gauge to “0”.

– Position the depth slide on the locking ring, as illustrated.
– Measure dimension “B1 ” on the locking ring in this position.
• Example: measurement “B1 ” = 2.62 mm

– Measure dimension “B2 ” on the opposite side of the locking

ring.

Note

Do not measure on the end of the locking ring. The circlip could

get pushed away and this would falsify the measurement.

• Example: dimension “B2 ” = 2.58 mm
– Calculate the mean value from “B1 ” and “B2 ”.

Formula: B1 + B2 2

Example:
• Refer to 2.62 + 2.582 = 2.60 mm
• Result: dimension “B” = 2.60 mm

Note

If the dual clutch continues to be installed according to this meas‐

urement, then it must be removed now. Refer to 

⇒ page 43

 .

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

49

it.

WARNING

Do not re-use the locking ring.

Step 2: Determine Dimension “A 1” for the “K 1” Clutch Engaging

Bearing.

– Install the large engaging lever.

WARNING

Do not install the shim.

– Make sure the engaging lever fits correctly.

– Place the Gauge - Clutch Bearings - T10466- on the large en‐

gaging bearing. The flat side faces up

– Press and turn the Gauge - Clutch Bearings - T10466- to make

sure it seats correctly on the engaging bearing.

• The engaging bearing turns with the Gauge - Clutch Bearings

- T10466- .

50

the ruler 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 slide on the Gauge - Clutch Bearings -

T10466- , as illustrated.

– Measure dimension “A 1a ” on the Gauge - Clutch Bearings -

T10466- .

• Example: dimension “A 1a ” = 4.93 mm

– Measure dimension “A 1b ” on the other side of the Gauge -

Clutch Bearings - T10466- .

• Example: dimension “A 1b ” = 4.91 mm
– Calculate the average value from dimension “A 1a ” and “A

1b ”.
Formula: A 1a + A 1b 2

Example:
• 4.93 + 4.912 = 4.92 mm
• Result: dimension “A 1” = 4.92mm
Step 3: Determine the Height Tolerance for the “K 1” Clutch En‐

gaging Bearing.

Note

Using dimension “A 1” and dimension “B”, calculate the height

tolerance for clutch “K 1” engaging bearing as follows:

 

Dimension “A 1”

Dimension “B”

=

Height tolerance for clutch “K 1” engaging bearing

Example:
• 4.92 mm – 2.60 mm = 2.32 mm
• Result: height tolerance for “K 1” clutch engaging bearing =

2.32 mm

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

51

illustrated.

• Result: clutch “K 1” clutch tolerance = + 0.20 mm.
Step 5: Determine the “SK 1” Shim Thickness.

Note

Using the clutch tolerance of clutch “K 1”, now the thickness of

shim “SK 1” can be calculated as follows:

 

Height tolerance for the engaging bearing “K 1”

–/+ Clutch tolerance for clutch “K 1”
=

Calculated thickness for shim “SK 1”

Example:
• 2.32 mm + 0.20 mm = 2.52 mm
• Result: calculated “SK 1” shim thickness= 2.52 mm

– Select the shim from the table using the part number

-magnifying glass- on the shim and lay it nearby for installation.

Calculated Shim

Thickness

mm

Available Shim

Thicknesses in mm

Shim Part Number

1.21 to 1.60

1.50

0AM 141 383

1.61 to 1.80

1.70

0AM 141 383 A

1.81 to 2.00

1.90

0AM 141 383 B

2.01 to 2.20

2.10

0AM 141 383 C

2.21 to 2.40

2.30

0AM 141 383 D

2.41 to 2.60

2.50

0AM 141 383 E

2.61 to 2.80

2.70

0AM 141 383 F

2.81 to 3.00

2.90

0AM 141 383 G

3.01 to 3.20

3.10

0AM 141 383 H

3.21 to 3.40

3.30

0AM 141 383 J

3.41 to 3.80

3.50

0AM 141 383 K

Example:
• Result: calculated “SK 1” shim thickness= 2.52 mm
• Selected shim thickness = 2.50 mm = part number 0AM 141

383 E

Caution

Only install these shims later to avoid damaging the clutch.

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