Contents: Removal ⬇ Installation ⬇
Removal
Note:
- The clutch housing cover is held in position by a retaining ring. After removing the retaining ring, the clutch housing cover can be removed.
- The clutch housing cover and retaining ring must always be replaced after disassembly.
- Never use a hammer to install a new clutch housing cover and never touch the middle seal with your hand or lubricate the seal with oil!
- When working on the clutch housing cover, the gearbox must be removed.
1. Remove the gearbox assembly (for more details, see the relevant section in this chapter).
Note: Oil can only be drained through the oil level check plug (arrow).
2. Unscrew the level control screw (arrow) located near the rocking support.
Note: Behind this threaded plug is a plastic bypass pipe with an 8 mm Allen key and a tightening torque of 3 N·m. The length of the bypass pipe determines the transmission oil level; when replacing this pipe, select the correct part number.
3. Remove the bypass pipe. It will leak approx. 5.0 liters of oil. Leave the catch basin under the gearbox from now on. After screwing on the bypass pipe, tighten it using the appropriate tightening torque.
4. Unscrew the oil filter housing (1) from the gearbox, as shown in the figure below.
5. Before you begin removing the oil filter housing, you need to tilt it slightly. This allows oil to drain from the oil filter back into the gearbox.
6. The O-ring (2) shown in the figure below should always be replaced.
7. Remove the filter (3) as shown in the figure below.
8. Lubricate the new O-ring (2) with transmission oil as shown in the figure below.
Note: There is no need to replace the oil filter after every oil change. Therefore, please follow the instructions when it is necessary to change the oil filter.
9. Lubricate the O-ring in the flange (arrow) of the new oil filter with transmission oil as shown in the figure below.
10. With the new oil filter installed with the shoulder (arrow) facing downwards as shown in the figure below, tighten the filter housing to the specified tightening torque.
11. After repair, there is no need to change the filter again when refilling with oil.
12. Remove the retaining ring from the clutch housing cover.
13. The clutch housing cover can be removed using a screwdriver.
14. Install only a new clutch housing cover.
Installation
Clutch housing covers without bushings
Note:
- The clutch housing cover and snap ring must always be replaced.
- Never use a hammer to install a new clutch housing cover and never touch the middle seal with your hand or lubricate the seal with oil!
Attention:
- In the case of a new clutch housing cover, the center hole must never be touched. Do not touch the clutch housing cover in this area, do not lubricate it, and make sure that it does not come into contact with other substances. The opposite would result in a breach of the seal.
- The clutch housing cover (A) may only be held in the hand in the manner shown in the figure!
Note:
Necessary special devices, control and measuring instruments, as well as auxiliary means
- The assembly sleeve (T10302) must be cleaned before use; do not use a scratched assembly sleeve.
The new clutch housing cover must be dry and free of oil on the sealing area in the middle!
1. If necessary, clean the end of the shaft of the gearbox clutch housing cover. Only the seal on the outer edge can be lubricated with transmission oil for DSG automatic transmissions.
2. The assembly sleeve (T10302) should be placed on a flat surface.
3. The center seal (B) of the new clutch housing cover (A) must be pre-formed:
- The clutch housing cover should be placed onto the assembly sleeve (T10302) horizontally and evenly along its entire length. This brings the working edge of the seal into position for assembly.
- The assembly sleeve (T10302) should be pulled out of the clutch housing cover in an upward direction and placed onto the end of the gearbox clutch housing cover shaft.
4. After inserting the clutch housing cover (A) through the assembly sleeve (T10302), press it evenly into the assembly position as shown in the figure below.
Caution: Work with caution. Any impact, even very light ones, would undoubtedly lead to a breach of the seal.
5. It is possible to install the clutch housing cover into the assembly position (arrow) carefully using a screwdriver (1) so that the new retaining ring can be installed as shown in the figure below.
6. Install a new retaining ring.
Clutch housing cover with bushing
Note:
- The clutch housing cover and snap ring must always be replaced.
- Never use a hammer to install a new clutch housing cover and never touch the middle seal with your hand or lubricate the seal with oil!
Caution: When replacing a new clutch housing cover, never touch the center hole. Do not touch the clutch housing cover in this area, do not lubricate it, and make sure that it does not come into contact with other substances. The opposite would result in a breach of the seal.
- The bushing should not be removed!
- The new clutch housing cover must be dry and free of oil on the sealing area in the middle!
1. If necessary, clean the end of the shaft of the gearbox clutch housing cover. There must not be any stickers on the inside of the clutch housing cover.
2. If the latter are present, they must be carefully removed! Only the seal on the outer edge can be lubricated with transmission fluid for DSG automatic transmissions.
3. Put on the clutch housing cover with the sleeve.
Caution: Work with caution. Any impact, even very light ones, would undoubtedly lead to a breach of the seal.
4. It is possible to install the clutch housing cover into the assembly position (arrow) carefully using a screwdriver (1) so that the new retaining ring can be installed as shown in the figure below.
5. Install a new retaining ring.
6. The bushing should be removed only after installing the retaining ring.
