Attention! When replacing the dual clutch, it is necessary to replace the following parts at the same time: both engagement levers with release bearings, the spherical journal of the engagement lever of the "K2" clutch, the adjusting washers of the release bearings. After replacing the dual clutch and the above parts, it is necessary to re-adjust the position of the release bearings of the friction clutches "K1" and "K2". Adjustment is not required if the above parts were simply removed and installed in place. The retaining ring must be replaced in each case. The large adjusting washer for the "K1" clutch is installed with the semicircular side down on the large bearing, the small adjusting washer for the "K2" clutch is placed under the small bearing.
Do not lubricate with oil or grease! Install the pivot bearing "1" and the spherical pin "2".
Insert the small engagement lever with the upper and lower parts of the guide sleeve. Tighten the screws to the specified torque.
Note: The engagement lever mount and the entire engagement bearing mechanism must be dry and free of oil or grease. If necessary, clean these parts with a rag.
Install the second, "large" engagement lever with specific clutch adjusting washers "K1" and "K2".
Note: The large adjusting washer for the "K1" clutch is installed with the semicircular side down on the large bearing, the small adjusting washer for the "K2" clutch is placed under the small bearing. The small engagement bearing and adjusting washer are installed on the 8 grooves in only one position.
Install the "small" engagement bearing. "Turn" to ensure that the bearing is installed correctly and the grooves are seated correctly. Check both engagement levers for proper seating.
Large adjusting washer for clutch "K1", small for clutch "K2". Unscrew the lead screw of puller "T10373". Install puller "T10373" on the clutch. Install the clutch in the gearbox with puller "T10373".
Note: The clutch automatically adjusts the working clearance. Vibrations can adversely affect the adjusting device. Therefore, the clutch must not be dropped. Also, when installing the clutch, do not drop the clutch in the gearbox.
Remove the puller "T10373" from the clutch. Install the support bridge "T10323" parallel to the flange of the clutch housing. Adjust the distances, for example, with washers "B" to a total thickness of 15 mm. Fasten the support bridge "T10323" with screws "A" and nuts. Press the clutch with the lead screw until it stops downwards.
Note: When pressing, place your hand on the clutch. Your hand should feel a slight rattling sound. The rattling sound means that the clutch is being pressed into the installation position. When the clutch is in place, you should feel a jolt. The clutch is pressed all the way in if the snap ring can be installed.
Snap ring installation position: The thinner side of the snap ring faces upward.
Install a new locking ring "see arrow".
Note: If the retaining ring is not inserted "see arrow", the clutch will not seat correctly in its place.
To get the clutch into place, you should turn it by hand using the puller. Turn the clutch only by hand, do not use a tool.
Turn by hand only. This way the clutch sits on the retaining ring. Do not use a tool. When pressing "the clutch sits lower" on the input shaft. The clutch should be pulled out just enough to touch the retaining ring.
Then install the disc hub: There is a "large" tooth on the disc hub, so the disc is installed in only one position. On the engine side, the "large" tooth is marked "see arrow".
Install the disc hub with the mark at the "large tooth" so that it coincides with the mark on the driven disc "see arrow".
Install the disc hub retaining ring "see arrow". Installation position: The joint of the ring should point to the "protrusion" on the clutch.
Turn the clutch by hand and while turning it, watch the "small" engagement lever.
The switch lever must remain "motionless" in its position. It must not move. If the switch lever moves, the adjusting washer is installed in the wrong position.
In this case, remove the clutch again. Make sure that the adjusting washer is installed correctly "see arrows". The washers must be installed correctly. They must not be damaged.
Remove the plugs and replace both breather units "see arrows".
Note: If the mechatronics breather is damaged during removal, it must be replaced.
After installing the control panel, perform the "Basic setup".