Volkswagen Golf Variant / Jetta. Manual - part 559

 

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Volkswagen Golf Variant / Jetta. Manual - part 559

 

 

illustrated.

Step 9: Determine the “SK 2” Shim Thickness.

Note

Using the clutch tolerance of clutch “K 2”, now the thickness of

shim “SK 2” can be calculated as follows:

 

Height tolerance for the engaging bearing “K 2”

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

Calculated thickness for shim “SK 2”

Example:
• 2.17 mm – 0.20 mm = 1.97 mm
• Result: calculated shim thickness “SK 2” = 1.97 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 shim thickness “SK 2” = 1.97 mm
• Selected shim thickness = 2.00 mm

WARNING

Only install these shims later to avoid damaging the clutch.

The adjustment is now complete and the »small« engaging lever

is already installed. The next step is to reinstall the clutch.
– Install the clutch. Refer to

⇒ “2.4 Dual Clutch, Installing, Transmission Production Date

from 06/2011”, page 58

 .

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

57

Dual Clutch, Installing, Transmission

Production Date from 06/2011

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-
Installing

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.

The hinge mount cannot be removed.
When replacing the dual clutch and its components, the “K 1

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

Refer 

to

⇒ “2.3  K 1 and K 2 Clutch Engaging Bearing Position, Adjust‐

ing, Transmission Production Date from 06/2011”, page 45

 .

The engaging lever support -1- and ball stud -2- are installed.

Note

Replace all bolts that were tightened with an additional turn.

The guide sleeve upper section cannot be removed or instal‐

led separately. It is always removed and installed together with

the guide sleeve lower section and the »small« engaging lev‐

er.

The Following Procedure Is Only Then Necessary If All of the

Components Mentioned are Removed and Reinstalled.

58

sections of the guide sleeve. Install new bolts and tighten

them.

Tightening specification. Refer to 

⇒ page 47

 .

Continuation for All

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.
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.

• Clutch components must have no oil or grease on them

when being installed.

– Install the »large« engaging lever with the measured shims for

“K 1” and “K 2” and with the small engaging bearing.

Note

The large shim in the large engaging bearing with the half-

round side facing down.

The small shim belongs under the small engaging bearing. In‐

stall the shim first.

The shim and the small engaging bearing fit only in one position

due to the 8 grooves.
– Turn and make sure the parts are installed correctly and fit

correctly in the grooves.

– Make sure both engaging levers fit correctly.
– Turn back the Puller - Clutch - T10373- spindle.

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.

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

59

- 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.

60

 

 

 

 

 

 

 

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