DSG(R) Clutch, Installing and Adjusting
DSG(R) Clutch, Installing and Adjusting
• The drive plate of the new clutch is not secured with the lock ring, it only sits "taut" in the clutch.
• Thus, press the drive plate down onto the outer clutch pack carrier with both thumbs during the following steps.
• The drive plate must be engaged between the teeth of the exterior clutch pack.
• If drive plate is loosened, the clutch discs in the Direct Shift Gearbox (DSG(R)) clutch can slip out of place and the clutch may not be correctly set during installation under certain circumstances.
- Take the DSG(R) clutch out of the packaging by pressing down on the drive plate onto the outer clutch pack carrier with both thumbs.
- Check the bottom side of the multi-plate clutch to see if the 4 hub seals are seated correctly and correct them, if necessary.
• The ends of the seals should not fold over one another.
- Turn the seals one time. They must move freely and must not stick.
Important! Installed position of the drive plate
- Verify that the protruding tab - arrow - of the drive plate is positioned between the color marked teeth on the outer clutch pack carrier.
If no mark is available:
- Mark the location of the tab to the outer clutch pack carrier circumference with a waterproof marker as shown in the illustration.
• When installing, the drive plate tab must be placed back on this marked location.
- Insert the retaining bar (T10303) in position on the clutch cover (as shown in illustration A30-10051).
- Set the DSG(R) clutch using rotating and hub movements into the clutch housing, but do not let it fall in. Press the drive plate onto the outer clutch pack carrier with both thumbs - arrows - to install.
• A second technician should hold the retaining bar (T10303).
• The retaining bar remains there until the clutch end cover is installed.
• The DSG(R) clutch must not be turned any more now, otherwise the retaining bar (T10303) could be twisted in its position.
- Remove the drive plate from the installed clutch - arrows -, if necessary, use a screwdriver to carefully pry it out of the teeth of the outer clutch pack carrier.
- Move the drive plate to the side.
Do not remove or lift the inner clutch pack carrier, under any circumstances. The clutch discs could rotate themselves.
Identify the lock ring for the DSG(R) clutch
- Select the 2 mm thick lock ring from the lock rings delivered and install it - arrow -.
• This lock ring is temporarily installed for the measurement of the axial play.
First Measurement:
• The retaining bar (T10303) remains installed.
- Install the dial gauge holder (VW 387) and a dial gauge to the transmission flange.
- Place the dial gauge button on the input shaft.
- Adjust the dial gauge pretension to "0".
- Raise the clutch up as far as the stop and note the measurement
Second Measurement:
• The retaining bar (T10303) remains installed.
- Place the dial gauge button on the hub of the large clutch pack carrier.
• The tip of the dial gauge may not be placed on the lock ring.
- Adjust the dial gauge pretension again to "0".
- Raise the clutch up as far as the stop again and note this measurement as well
Now the calculation will be made to determine which of the remaining nine lock rings will be finally installed:
- Use this formula:
2nd measured value - the 1st measured value + 1.85 mm = the lock ring thickness
- Write down the result.
The remaining nine lock rings are staggered in 0.1 mm increments.
- Measure all the lock rings and determine the one that is the closest match to the result
- Remove the 2 mm lock ring and replace it with the lock ring that was measured.
- Dispose of all other lock rings remaining and the 2 mm lock ring.
• The lock rings must only be installed one time.
- Insert the pump shaft.
• The pump shaft must be slightly lifted and rotated - arrow - in order for it to completely slide into the splines.
- Insert the drive plate into the DSG(R) clutch.
• The protruding tab of the drive plate must be positioned between the color marked teeth of the outer clutch pack carrier. Make note of marks that have been changed retrospectively.
- Install the new drive plate lock ring.
• The lock ring must be installed so that the tab of the drive plate - arrow - and the color marked teeth of the outer clutch pack carrier are positioned between both ends of the lock ring.
• The lock ring must be completely engaged.
- Check the exact installed position of the lock ring and that the lock ring is engaged using a screwdriver.
- Now remove the retaining bar (T10303) between the DSG(R) clutch and the housing.
- Install the clutch end cover. Refer to => [ Clutch End Cover, Installing ] Clutch End Cover, Installing.