Volkswagen Golf / Golf GTI / Golf Variant. Service manual - part 449

6

Special Tools

Special tools and workshop equipment required
♦ Not Illustrated:
♦ Engine Support Bridge - 10-222A-

30 – Clutch

1

Clutch

⇒ “1.1 Overview - Dual Clutch”, page 13
⇒ “1.2 Clutch End Cover, Removing and Installing”, page 15
⇒ “1.3 DSG® Clutch, Removing”, page 19
⇒ “1.4 DSG® Clutch, Installing”, page 21

1.1

Overview - Dual Clutch

Short Description
♦ The clutch contains two disc packs. The outer, larger disc pack

is called “K 1” (clutch 1). The “K 1” shifts reverse gear and “1st”,

“3rd” and “5th” gears. The inner, smaller “K 2” (clutch 2) shifts

the gears “2”, “4” and “6”.

♦ Assembling the DSG

®

 clutch requires special care, because

all of the components were balanced to each other at the

manufacturer. When positioning components during installa‐

tion, do no rotate them from their original position, otherwise

imbalances will occur, reducing the shift comfort and the life

span.

Replacement Part Package

1 - Dual Clutch with Circlip

Caution

♦

The drive plate (upper

section of the dual clutch)

of a new clutch is not se‐

cured with the circlip, it

only sits »taut« in the

clutch.

♦

The drive plate must re‐

main engaged between

the teeth of the outer

clutch plate carrier.

♦

If the drive plate is loos‐

ened, the clutch plates in

the dual clutch can slip

out of place. The dual

clutch may not be cor‐

rectly set during installa‐

tion under certain circum‐

stances.

2 - Circlip

❑ Quantity: 10, with vari‐

ous thicknesses for ad‐

justment

❑ When installing the dual

clutch, the thickness of

the circlip must be de‐

termined. Refer to

⇒ page 24

3 - Clutch End Cover
4 - Circlip

❑ For clutch end cover

Individual Parts of the Disassembled DSG

®

 Clutch

Caution

1 - DSG

®

 Clutch/Clutch Hous‐

ing

❑ Outer clutch pack carri‐

er

2 - Seals

❑ Quantity: 4

3 - Inner Clutch Pack Carrier

❑ Do not remove

Caution

Do not lift or remove the

inner clutch pack carrier,

under  any  circumstan‐

ces.  The  clutch  discs

could rotate themselves.

4 - Outer Discs

❑ Quantity: 4

5 - Inner Discs

❑ Quantity: 4

6 - Thrust Washer
7 - Circlip

❑ In the event the securing

ring was removed in or‐

der to reinsert discs, it

should be replaced with

a new ring of the same

thickness.

8 - Circlip

❑ After installing a new du‐

al clutch, redetermine

the thickness. Refer to

⇒ page 24

 .

9 - Drive Plate
10 - Circlip

❑ Replace after removing

1.2

Clutch End Cover, Removing and Instal‐

ling

Special tools and workshop equipment required
♦ Clutch Cover Plate Guide Sleeve - T10302-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Clutch End Cover
♦ Circlip - Clutch End Cover