Clutch, Installing and Adjusting

Clutch, Installing and Adjusting, 02E, 6 SPD. DSG A/T

CAUTION!
Prevent the removal or lifting of the clutch carrier. Not even slightly! The clutch discs can rotate themselves.

Note:
Transmission must be rotated vertically in assembly stand and opening for clutch must face upward. Only in this way is it later also possible to adjust the clutch axial play.
Transmission must always be clamped tightly in assembly stand. It must not be rotated.
In the clutch, the large clutch discs carrier installs all clutch discs, it must not be slipped out of lowest clutch disc.
Input shaft of transmission oil pump has been removed.

Special tools, testers and auxiliary items required





Holding Plate VW 309





Transmission Support VW 353





Dial Gauge Holder VW 387





Retaining Bar T10303

Dial gauge





- First, place Retaining Bar T10303 on to seat - arrow - of cap (sealing cap).





- Then, carefully insert clutch direction of - arrow - , do not let it fall in.





Retaining Bar T10303 must be held in place by a second technician when doing this.

Retaining Bar T10303 remains there until clutch cap has been installed.





- Determine the ring with 2 mm thickness - arrow - from all supplied securing rings and install it temporarily.

Before this ring is removed again, two measurements must be performed first.

First measurement:
Retaining Bar T10303 remains installed!





- Install Dial Gauge Holder VW 387 on to transmission flange.
- Place plunger of dial gauge on to transmission input shaft.
- Set dial gauge to "0" with pre-load.
- Lift clutch upward until it stops and note measurement result.

Second measurement:
Retaining Bar T10303 remains installed!





- Place plunger of dial gauge on to hub of large clutch discs carrier for clutch.

Note:
Plunger must not rest on the securing ring.

- Reset dial gauge to "0" with pre-load.
- Lift clutch upward again until it stops and note this result as well.

Now it will be calculated which of the nine remaining securing rings will be installed finally:

- For this, use this formula:
- Second measurement minus first measurement plus 1.85 mm = thickness of ring to be installed.
- Note this result.

The nine remaining securing rings are stepped in 0.1 mm increments.

- Measure all rings and then determine the ring which matches your result.
- Remove 2 millimeter thick ring and replace with determined ring.





- Insert input shaft for transmission oil pump, when doing this rotate slightly in direction of - arrow -.





- Insert clutch cap so that tab - arrow B - coincides with marking - arrow A - .
- Place new securing ring - 1 - into clutch.
- Remove Retaining Bar T10303 .
- Install cap (sealing cap) for clutch .

This concludes the installation, the clutch is correctly adjusted.

After installing transmission:

- Basic calibration of Direct Shift Gearbox (DSG) Mechatronic J743 is performed using Vehicle Diagnosis, Testing and Information System VAS 5051 or Vehicle Diagnosis Service Syst. VAS 5052 in "Guided Fault Finding" .