Dual Clutch

Dual Clutch

Special tools, testers and auxiliary items required

• Additional Hooks (10 - 222 A /2)

• Workshop Crane (VAS 6100)

• Pulling Hook (T20143/2)

• Puller for ATF Supply (T40123 A)

• Sleeve (T40123 A/1)

• Centering Tool (T40199)

Removing

• The transmission is secured on the Engine and Transmission Holder (VAS 6095). Refer to => [ Transmission, Securing to Engine and Transmission Holder ] Transmission, Securing to Engine and Transmission Holder.

- Remove dual mass flywheel. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel.

- Draining ATF. Refer to => [ ATF, Draining or Filling after Repair ] ATF, Draining or Filling after Repair.

- Pry out the input shaft seal using Hook (T20143/2).





- Remove bolts - 1 through 5 -.





- Turn the transmission in the Engine and Transmission Holder (VAS 6095) so that it is vertical.

- Push the Sleeve (T40123 A/1) onto the input shaft.





- Position the Lifting Device (T40123 A) on the input shaft.

• The edge - arrow - of the lifting device must grip under the Sleeve (T40123 A/1).

- Close the lifting device and tighten the knurled nut - 1 - to approximately 20 Nm.

- Make sure the lifting device fits securely on the input shaft.

- Connect the Lifting Device (T40123 A) to the Supplementary Hook (10 - 222 A /2) and attach to the Shop Crane (VAS 6100).





- Carefully remove the dual clutch out of the transmission housing.

- Lay the dual clutch and cover on a soft surface so that the thin rib - arrow A - does not get damaged.





- Remove circlip - arrow - using pliers.





- Remove clutch cover - 2 - from the dual clutch - 1 -.





• If the clutch cover does not come off, gently strike the input shaft with a rubber hammer while a second technician lifts the clutch cover by hand.

• Be careful not to damage the thin rib - arrow A - when doing this.





Installing

Install in reverse order, paying attention to the following:

• Replace the O-ring and circlip.

- Clean the sealing surface on the clutch cover.

- Turn rectangular rings - B - on the hub and check for ease of movement and axial play.

• If the rectangular rings do not move easily, then the dual clutch must not be installed.

- Clean transmission housing around the dual clutch and the sealing surface.





• Be careful that no dirt falls into the transmission while cleaning.

- Install Assembly Pin (T40199) into the threaded hole in the transmission housing as illustrated.

- Check the hole - arrow - in the transmission for wear grooves.





- Coat O-ring - C - and hub - B - on the dual clutch with ATF.





- Install the dual clutch into the transmission housing. Using short lifting/turning motions, allow the input shaft to engage into the ATF pump splines and transmission shafts as illustrated.





• The dual clutch is installed correctly when the clutch cover O-ring noticeably contact the edge of the transmission housing.







CAUTION!
• Do not let the O-ring get caught when installing.

• Always follow the tightening sequence when tightening the bolts for the dual clutch and clutch cover => [ Tightening specification and sequence for the
dual clutch and clutch cover ] Dual Mass Flywheel and Dual Clutch Assembly Overview

- Input Shaft Seal, Removing and Installing. Refer to => [ Input Shaft Seal ] Input Shaft Seal.

- Install dual mass flywheel. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel.

- Fill ATF after the transmission is installed. Refer to => [ ATF, Draining or Filling after Repair ] ATF, Draining or Filling after Repair.