02EA (S-Tronic) Transmission
Multi-Plate Clutch
Special tools, testers and auxiliary items required
• Guide Sleeve (T10302)
• Retaining Bar (T10303)
• Dial Gauge Holder (VW 387)
• Clean the (T10302) before using, do not use any scratched sleeves.
Removing
• Transmission, securing to engine and transmission holder, refer to => [ Transmission, Securing in Engine/Transmission Holder ] Transmission, Securing In Engine/Transmission Holder.
- Drain the transmission fluid. Refer to => [ Transmission Fluid, Replacing or Filling after Repair ] Transmission Fluid, Replacing or Filling After Repair.
- Replace the transmission oil filter. Refer to => [ Transmission Fluid Filter ] Transmission Fluid Filter.
- Remove the ring - 2 - from the clutch end cover with a screwdriver - 1 - - arrow -.
- Remove the clutch end cover - 2 - through the opening for the starter using a screwdriver - 1 - or a pry bar - arrow -.
- Remove the locking ring - 2 - from the drive plate with a screwdriver - 1 - - arrow -.
- Remove the drive plate - arrows -.
- Remove the locking ring - arrow - using a screwdriver or needle nose pliers.
- Remove multi-plate clutch from the transmission.
- When the multi-plate clutch is removed, check whether clutch bell housing was damaged during removal.
- Pull out the pump shaft - A - and lay it to the side.
Installing
Risk of discs in multi-plate clutch slipping.
• If the drive plate comes out of the outer clutch pack carrier teeth, the plates can slip. The multi-plate clutch can no longer be adjusted correctly.
• To ensure multi-plate clutch discs do not slip, press drive plate into outer clutch pack carrier with thumbs during all of the following steps.
• The drive plate circlip delivered in the replacement parts package will be installed later.
- Remove the new drive plate circlip from packaging and lay it aside.
- Remove the multi-plate clutch from packaging while securing drive plate.
- Install the old drive plate locking ring - A - in the multiplate clutch removed earlier.
• Installed position: Drive plate tab and outer clutch pack carrier teeth marked in color must lie between ends of circlip.
- Using a screwdriver, make sure the circlip is completely engaged.
- On the bottom side of multi-plate clutch, check whether the hub sealing rings are seated correctly and engage them in one another if necessary.
• Installed position: Ends of rings offset to one another.
- Position the (T10303) on the clutch end plate seat as illustrated.
- Insert the multi-plate clutch in the clutch bell housing by turning and lifting and pressing drive plate into outer clutch pack carrier with both thumbs - arrows -.
• Do not let the multi-plate clutch fall into the inner clutch pack carrier.
- Have a second technician hold the (T10303) as illustrated until clutch end plate is installed.
• To prevent the (T10303) from rotating in place, do not rotate multi-plate clutch.
- Verify that the protruding tab - arrow - of the drive plate is positioned between the color-marked teeth of the outer clutch pack carrier.
- If there is no marking, mark the location of the drive plate to outer clutch pack carrier circumference for reinstallation with a waterproof marker as shown in the illustration.
• When installing, drive plate tab must be placed back on this marked location.
- Remove the old locking ring - 2 - with a screwdriver - 1 - - arrow -.
Risk of discs in multi-plate clutch slipping.
• If the inner clutch pack carrier is removed or raised, discs can slip. The multi-plate clutch can no longer be adjusted correctly.
- Remove the drive plate - arrows -. If necessary, carefully pry the drive plate out of the outer clutch pack carrier teeth using a screwdriver.
- Move the drive plate to the side.
Multi-plate clutch, adjusting (determine circlip thickness)
- Find the 2 mm thick circlips in the replacement parts package.
• For the initial measurement, temporarily insert 2 mm thick circlip and then, after the measurement has been determined, replace it with the final circlip.
- Insert a 2 mm locking ring - arrow -.
- Attach (VW 387) to transmission flange.
- For the 1st measurement, place dial gauge measuring tip on input shaft, as show in the illustration.
- Set the dial gauge with 2 mm preload to "0".
- Raise the multi-plate clutch all the way up.
- Read the measurement (= input shaft axial play) and note.
- For the 2nd measurement, place dial gauge measuring tip on inner clutch pack carrier hub, as show in the illustration.
• Measuring tip must not be placed on circlip.
- Set the dial gauge with 2 mm preload to "0".
- Raise the multi-plate clutch all the way up.
- Read the measurement and note.
The new circlip will be determined according to the following formula:
Circlip = 2nd measurement - 1st measurement + 1.85 (= constant value)
The new circlips are staggered in 0.1 mm increments. Round to the closest number when selecting: Up to 0.049, round down, from 0.050, round up.
Example:
• Measurement determined for new circlip 2.27 mm, new circlip rounded up to 2.3 mm thick.
• Measurement determined for new circlip 2.24 mm, new circlip rounded down to 2.2 mm thick.
• If the measurement determined for the new circlip is 2 mm, the circlip that was inserted temporarily remains installed.
- Remove 2 mm thick circlip that was inserted temporarily for the measurement and replace with circlip thickness just determined.
• The circlips may be used only one time.
• Dispose of the removed circlip that was inserted temporarily as well as the remaining circlips.
- Insert pump shaft by raising shaft and turning slightly - arrow - so it engages completely in splines.
- Insert drive plate in multi-plate clutch.
• The protruding tab on the drive plate - arrow - must be installed between the marked teeth or the marking applied to the outer clutch pack carrier.
- Install the new drive plate circlip.
• Installed position: The drive plate tab and marked teeth or outer clutch pack carrier marking that was applied must lie between the ends of the circlip.
- Using a screwdriver, make sure the circlip is completely engaged.
- Remove the (T10303) between the multi-plate clutch and the housing.
Risk of leaking at clutch end cover contact surface.
• Lubricate clutch end cover inner seal contact surface on drive plate - arrow -.
- Clean clutch end cover outer seal contact surface.
Risk of leaking at clutch end cover inner seal.
• To ensure the inner seal remains absolutely free of oil, do not touch seal with hands.
- Remove the clutch end cover from the replacement parts package, only touching cover on outer edge.
- Clean the end of transmission shaft.
• Only the clutch end cover outer seal may be coated with gear oil.
• If there are stickers on the outside or inside of the clutch end cover, they must be removed without leaving any residue.
- Place the (T10302) on a level surface.
- To form the inner seal to the new clutch end cover, guide clutch end cover with outer side down evenly and horizontally over the (T10302).
- Remove the (T10302) upward out of the clutch end cover.
- Place the (T10302) on the end of the multi-plate clutch shaft.
Risk of damaging clutch end cover.
• Do not drive clutch end cover on with hammer.
- Guide the clutch end cover with outer side up horizontally over the (T10302) and press it evenly into the seat.
- If necessary, carefully pry clutch end cover into seat with a screwdriver - arrow -, as illustrated until it is possible to install the shaft ring.
- Install clutch end cover shaft ring in transmission housing by counter holding shaft ring on the opposite side so it remains in its groove.
- Using a screwdriver, make sure the shaft ring is completely engaged.
- Fill the transmission fluid for the S-Tronic transmission after installing it. Refer to => [ Transmission Fluid, Replacing or Filling after Repair ] Transmission Fluid, Replacing or Filling After Repair.
- Perform a basic setting using the vehicle diagnostic tester.