Volkswagen Golf Variant / Jetta. Manual - part 560

 

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Volkswagen Golf Variant / Jetta. Manual - part 560

 

 

without using any other tools so that it can move into its oper‐

ating position in direction of -arrow-.

Note

The clutch sits on the stop at the bottom of the input shaft. This

is not its optimal position.

The clutch should be pulled up just far enough until it touches

the locking ring.

Note

Only turn it by hand. This way the clutch slides against the locking

ring. Do not use any other tool.

– Install the hub.
• The hub as a single »large tooth« -arrow- and fits in only one

position.

• The »large tooth« has a marking on the engine side.

– Insert the locking ring -arrow-.
• The end of the locking ring must face the »nose« on the clutch.

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

61

Note

Remove the clutch if it is difficult to turn or if the it grinds against

the clutch plates while being turned. Refer to

⇒ “2.2 Dual Clutch, Removing, Transmission Production Date

from 06/2011”, page 42

 .

Check the installed position of the shims -arrows-.

The shims must fit correctly and must not be damaged. Refer

to

⇒ “2.4 Dual Clutch, Installing, Transmission Production Date

from 06/2011”, page 58

 .

It is possible there was a calculation error. Check the meas‐

urements one more time. Refer to

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

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

 .

If there is no error, then it is possible the clutch shifted during

transportation/assembly. In this case it is necessary to install

a new clutch. Then it is necessary to adjust the position of the

engaging bearing again. Refer to

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

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

 .

– Remove both plugs and mount the vent caps -arrows-.

WARNING

The vent cap on the Mechatronic will be destroyed during re‐

moval and must be replaced.

– After installing the transmission, perform the 

Complete basic

setting

 using 

Guided Functions

 in the Vehicle Diagnostic

Tester .

62

Clutch-Side Seals, Removing and In‐

stalling

Replacing the Input Shaft Seal
There are 2 seals in the transmission on the clutch side. It is pos‐

sible to replace both seals -arrows- without disassembling the

transmission. It is not necessary to adjust the clutch if only the

seals are being replaced.

Special tools and workshop equipment required
♦ Press Piece - 60mm - VW415A-
♦ Puller - Shaft Seal - T10420-
♦ Seal Installer - Shaft Seal - T10421-
♦ Puller - Crankshaft/Power Steering Seal - T20143/2-
– Remove the transmission:
♦ Refer to

⇒ “4 Transmission, Removing and Installing, Jetta from MY

2005, Golf Wagon from MY 2007 and Golf Wagon from MY

2010”, page 127

♦ Refer to

⇒ “5 Transmission, Removing and Installing, Jetta from MY

2011”, page 166

– Dual Clutch, Removing:
♦ through Transmission Production Date 05/2011. Refer to

⇒ “1 Dual Clutch, Removing and Installing, through Transmis‐

sion Production Date 05/2011”, page 15

♦ from Transmission Production Date 06/2011. Refer to

⇒ “2 Dual Clutch, Removing and Installing, from Transmission

Production Date 06/2011”, page 40

 .

Caution

Always check the clutch if there are leaks. The dual clutch must

be replaced if it is covered with fluid.

3. Clutch-Side Seals, Removing and Installing    

63

– Drive in the outer, »new« seal flush to the clutch housing using

a plastic mallet.

• The Press Piece - 60mm - VW415A- offset points upward

-arrow-.

WARNING

Install the seal flush with the clutch housing so that the oil bore

behind  it  is  not  sealed.  Otherwise  the  outer  input  shaft  ball

bearing will not have enough oil.

– Remove the Puller - Shaft Seal - T10420- spindle.

– Install the Puller - Shaft Seal - T10420- on the »small«, inner

seal. Press on the Puller - Shaft Seal when doing so.

The Puller - Shaft Seal will jam the seal when it is being turned It

can be »felt« when the seal begins to move in its place.

– Now install the spindle.
– Remove the seal using the spindle.

64

 

 

 

 

 

 

 

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