16.1 Double clutch assembly parts
1 Retaining ring
2 Plate support, do not attempt to remove or lift even slightly
3 Double clutch housing, with clutch installed "K2"
4 O-rings, 4 pcs.
5 Outer plates, 4 pcs.
6 Inner plates x 4
7 Support washer
8 Retaining ring, after removing to install new plates, install a new ring of the same thickness
9 Clutch cover
10 Retaining ring, must be replaced, do not install wavy retaining rings
Removal / installation of the clutch cover
2. The clutch cover is held in place by a retaining ring, after removing which the cover can be lifted. The cover and retaining ring must be replaced after removal. Never install a new cover with a hammer, do not take it by the center hole and do not lubricate the center seal, otherwise leakage will occur (see illustration 16.2a). Handle the new cap only as shown in illustration 16.2b.
16.2a Do not touch the middle spacer
16.2b Holding the clutch cover
3. Remove DSG (see Section 15).
4. Remove the service port plug (B in Illustration 21.11 of Chapter 1) next to the swinging support, and then unscrew the overflow pipe located behind this plug, approximately 5 liters of working fluid will pour out. Screw in the overflow tube.
5. Unscrew the cover (1 in Illustration 21.6 of Chapter 1), slightly tilt the filter (3), so that the working fluid from it glass in the DSG, and remove the filter. Install a new o-ring (2), lubricated with DSG fluid.
6. Moisten the O-ring in the receiving sleeve (see Figure 21.7 Chapter 1), install a new filter and tighten its cap to 20 Nm.
7. Fill DSG with fresh fluid (see Section 21 of Chapter 1).
8. Remove the retaining ring of the clutch cover and remove it by lifting it with a screwdriver.
9. The clutch cover can be supplied with or without a bushing. Installation of a clutch without a bushing is described in paragraphs 10-13, and installation of a clutch with a sleeve is described in paragraphs 14-16.
10. Clean the T10302 mounting sleeve and make sure it is not scratched. Make sure the new clutch cover is dry and the center seal is free of grease. If necessary, clean the end of the clutch shaft. Only the seal on the outer edge of the cover can be lubricated with DSG hydraulic fluid. Place bushing T10302 on a flat surface.
11. Deform the center seal (B on resist. illustrations) new cover (A) clutch. To do this, slide the cover evenly and horizontally onto the T10302 sleeve, - the sealing lip is brought into the installation position. Remove the sleeve from the cover in an upward direction and install the sleeve on the end of the clutch shaft.
16.11 Deformation of the central seal
12. Screw on the lid (And on the opposite illustrations) through bushing T10302 and slide evenly into the installation position. Do not allow even the slightest distortion.
16.12 Installing the cover supplied without a sleeve
Note: Tool T30109 is used to mount the DSG.
13. Install a new retaining ring. While the retaining ring is not installed, you can gently pry off the cover with a screwdriver (1 per resist. illustrations) in her position (arrow).
16.13 Fitting the circlip
14. Do not remove the sleeve from the cover. Make sure the new clutch cover is dry and the center seal is free of grease. If necessary, clean the end of the clutch shaft. Only the seal on the outer edge of the cover can be lubricated with DSG hydraulic fluid. Place bushing T10302 on a flat surface.
15. Install the cover with the sleeve (see resist. illustration), without even the slightest distortion. Install a new retaining ring. While the retaining ring is not installed, you can gently pry off the cover with a screwdriver (1 in illustration 16.13) in her position (arrow).
16.15 Fitting the cover supplied with the sleeve
16. After installing the retaining ring, you can remove the bushing.
Removing/installing the clutch
17. Remove DSG (see Section 15) and fasten it vertically so that the grip is on top.
18. Remove the clutch cover (see subsection above). Remove retaining ring (arrow on resist illustrations) and remove the cover (1).
16.18 Circlip of the clutch cover
19. Remove retaining ring (see resist. illustration). Measure the thickness of this ring and prepare a new circlip of the same thickness.
16.19 Clutch retaining ring
20. Carefully remove the clutch (And on the opposite illustrations) in the direction of the arrow without turning it to prevent the base plate or other clutch parts from falling off. If the clutch has fallen apart, assemble it in accordance with illustration 16.1.
16.20 Removing the clutch
21. Pull out the drive shaft (And on the opposite illustrations) pump and set it aside. The drive shaft is inserted only after the installation of a new clutch.
16.21 Pulling out the pump drive shaft
22. Details of the supplied clutch are shown on Ref. illustrations. New clutch cover not secured with circlip (5), it is seated in the clutch with a slight interference to prevent the clutch parts from falling off during transport. Before installing the clutch, the cover can be carefully removed.
16.22 Details of the supplied clutch
1 Clutch
2 10 circlips of various thicknesses, in 0.1 mm increments
3 Clutch cover, a bushing is installed to protect the central seal, which should not be removed
4 Cover retaining ring 3
5 Cover retaining ring 3, do not install wave rings
23. Remove the new clutch from its packaging by applying pressure on its lid to prevent the lid and base plate underneath from slipping off the inner plates. Pay attention to the correct position of the four piston rings (And on the opposite illustrations), - their joints should not be on top of each other. Try turning the rings - they should move freely, without jamming.
16.23 Piston rings
24. Make sure you have a label (And on the opposite illustrations) on the clutch. If there is no mark, apply it with a marker opposite the foot (IN) clutch covers. When installing the foot of the lid, it will be necessary to place it opposite this mark. If the cover is installed on a new clutch, remove the retaining ring (1).
16.24 Lid position
25. Carefully remove the clutch cover in the direction of the arrows (see resist. illustration) and put it aside. Do not remove or attempt to raise the plate support, otherwise the plates may rotate. Set the clutch aside so that it does not fall.
16.25 Removing the cover
26. Install the holding tool T1 0303 on the seating surface (arrow on resist illustrations) clutch covers.
16.26 Installing tool T10303
27. Have a helper hold tool T10303 (see resist. illustration) and carefully install the clutch in the opposite direction of the arrow (see illustration 16.20), without falling. Do not remove tool T10303 until the clutch cover is installed.
16.27 Holding tool T10303
28. Select a 2 mm thick retaining ring from the clutch kit and temporarily install it (see illustration 16.19).
29. Mount the holder MP3-447 or VW387 with a plunger indicator on the DSG flange. Push the indicator plunger into the DSG drive shaft (see illustration 16.29a), reset the indicator, raise the clutch all the way up and record the result. Then seat the indicator plunger against the hub of the large base plate against the circlip gap (see illustration 16.29b), reset the indicator, raise the clutch all the way up and record the result. Determine the thickness of the required retaining ring. To do this, subtract the first from the second measurement result, add 1.85 mm and round down to 0.1 mm. Remove the temporarily installed 2.0 mm thick retaining ring and replace it with a retaining ring of the correct thickness.
16.29a Measurement #2
16.29b Dimension #2
Note: Retaining rings may only be installed once.
30. Insert the pump drive shaft, turning it slightly (see resist. illustration).
16.30 Installing the pump drive shaft
31. Insert the clutch cover so that its tab (B in illustration 16.24) was aligned with the label (A) on the clutch. Install a new retaining ring (1).
32. Remove tool T10303 and install the clutch cover (see subsection above).
33. Install the DSG and, using the scan tool, apply the basic settings for the unit "Mechatronic".