VW Golf manuals

Volkswagen Golf Service & Repair Manual: Adjusting clutch engagement

The position of the engagement bearings “K 1” and “K 2” must only be adjusted after the following work:
Clutch has been renewed.
Engaging levers were renewed.
Small ball pin for engaging lever “K 2” has been renewed.
Engagement bearings were renewed.
  Note
There is no need to adjust anything if all the named parts have only been removed and reinstalled.
The retaining ring must be renewed in each case.
Special tools and workshop equipment required
   
Gauge block -T10466-
 

Adjusting clutch engagement

Ruler -T40100-
Not shown: Depth gauge, digital 300 mm -VAS 6594-
Conditions
Dual clutch removed → Chapter.
The gearbox flange must be level to assure good contact with the ruler.
Mechatronic unit for dual clutch gearbox -J743- built into gearbox.
  Caution
Risk of damage to clutch and other components!
Mounting for engaging lever and entire mechanism of engagement bearing must be dry and free of oil or grease.
 

Adjusting clutch engagement

Removing and installing ball pin
–  Use pliers to remove ball-head pin.
 

Adjusting clutch engagement

–  Push in »new« ball pin by hand, if necessary using a plastic hammer and drift to tap it in.
  Note
To avoid damage to ball pin, only tap the drift lightly with the plastic head hammer.
 

Adjusting clutch engagement

Continuation for all:
  Note
If dimension “B” has already been determined, it is now possible to proceed with step “2” of the measurement → Anchor
–  Install previously used retaining ring -arrow- of outer input shaft.
 

Adjusting clutch engagement

1st step: Determine dimension “B” for clutch “K 1” and “K 2”
 

Adjusting clutch engagement

–  Place ruler -T40100- upwards across end of shaft onto gearbox flange.
  Caution
Risk of false measurements.
The ruler -T40100- should remain in this position for the following measurements. Do not turn over, do not remove.
 

Adjusting clutch engagement

–  Fit digital 300 mm depth gauge -VAS 6594- on top of ruler -T40100-. Position depth gauge rod on outer input shaft.
–  Set depth gauge to “0”.
 

Adjusting clutch engagement

–  Position depth gauge rod on retaining ring, as show in diagram.
–  In this position, determine dimension “B1” to retaining ring.
Example: dimension “B1” = 2.62 mm
 

Adjusting clutch engagement

–  In the opposite position, determine dimension “B2” to retaining ring.
  Note
Do not measure on retaining ring joint. The retaining ring could be pushed away and falsify the reading.
Example: dimension “B2” = 2.58 mm
–  Calculate mean value from dimension “B1” and “B2”.
   Formula:
B1 + B2
2
Example:
2.62 + 2.58
2
= 2.60 mm
Result: Dimension “B” = 2.60 mm
  Note
If the dual clutch is still installed following this measurement, it must now be removed → Anchor.
 

Adjusting clutch engagement

–  Remove retaining ring -arrow- of outer input shaft and dispose.
  Note
It is not permissible to reuse the retaining ring.
 

Adjusting clutch engagement

2nd step: Determine dimension “A 1” for clutch engagement bearing “K 1”
 

Adjusting clutch engagement

–  Insert large engaging lever.
  Caution
Risk of false measurements.
Do not insert any shim!
–  Check that engaging lever is seated correctly.
 

Adjusting clutch engagement

–  Place end gauge -T10466- on large engagement bearing. Flat side faces upwards.
–  To ensure that end gauge -T10466- sits properly on engagement bearing, press down and turn end gauge.
Engagement bearing will turn with end gauge -T10466-.
 

Adjusting clutch engagement

–  Fit digital 300 mm depth gauge -VAS 6594- on top of ruler. Position depth gauge rod on outer input shaft.
Ruler -T40100- is lying upwards across end of shaft on gearbox flange.
  Caution
Risk of false measurements.
The ruler -T40100- should remain in this position for the following measurements. Do not turn over, do not remove.
–  Set depth gauge to “0”.
 

Adjusting clutch engagement

–  Position depth gauge rod on end gauge -T10466-, as show in diagram.
–  In this position, determine dimension “A 1a” to end gauge -T10466-.
Example: Dimension “A 1a” = 5.03 mm
 

Adjusting clutch engagement

–  In the opposite position, determine dimension “A 1b” to end gauge -T10466-.
Example: Dimension “A 1b” = 5.01 mm
–  Calculate mean value from dimension “A 1a” and “A 1b”.
   Formula:
A 1a + A 1b
2
Example:
5.03 + 5.01
2
= 5.02 mm
Result: Dimension “A 1” = 5.02 mm
3rd step: Calculate height tolerance of clutch engagement bearing “K 1”
  Note
On the basis of dimension “A 1” and dimension “B”, the height tolerance of the engagement bearing for clutch “K 1” is now calculated according to the following calculus.
 

Adjusting clutch engagement

  Dimension “A 1”
Dimension “B”
= Actual height tolerance of clutch engagement bearing “K 1”
 
Example:
5.02 mm – 2.60 mm = 2.42 mm
Result: Height tolerance of clutch engagement bearing “K 1” = 2.42 mm
   
4th step: Determine clutch tolerance of clutch “K 1”
–  Read clutch tolerance value from new clutch.
Example: Read off clutch tolerance value on clutch “K 1 = +0.2”, as shown in diagram.
Result: Clutch tolerance of clutch “K 1” = + 0.20 mm.
5th step: Determine thickness of shim “SK 1”
  Note
On the basis of the clutch tolerance “K 1”, the thickness of shim “SK1” is now calculated according to the following calculus.
 

Adjusting clutch engagement

  Height tolerance of engagement bearing “K 1”
–/+ Clutch tolerance of clutch “K 1”
= Calculated thickness of shim “SK 1”
 
Example:
2.42 mm + 0.20 mm = 2.62 mm
Result: Calculated thickness of shim “SK 1” = 2.62 mm
   
–  Select required shim from the table with the help of the part number -magnifying glass- and have it ready for installation.
 

Adjusting clutch engagement

Calculated thickness of shim mm Available shims Thickness in mm Part number of shim
1.21 … 1.60 1.50 0AM 141 383
1.61 … 1.80 1.70 0AM 141 383 A
1.81 … 2.00 1.90 0AM 141 383 B
2.01 … 2.20 2.10 0AM 141 383 C
2.21 … 2.40 2.30 0AM 141 383 D
2.41 … 2.60 2.50 0AM 141 383 E
2.61 … 2.80 2.70 0AM 141 383 F
2.81 … 3.00 2.90 0AM 141 383 G
3.01 … 3.20 3.10 0AM 141 383 H
3.21 … 3.40 3.30 0AM 141 383 J
3.41 … 3.80 3.50 0AM 141 383 K
 
Example:
Result: Calculated thickness of shim “SK 1” = 2.62 mm
Chosen shim thickness = 2.70 mm = part number 0AM 141 383 F
  Caution
The clutch can be damaged.
Install only this shim later when required.
   
–  Remove end gauge -T10466- and large engagement lever again.
 

Adjusting clutch engagement

6th step: Determine dimension “A 2” for clutch engaging lever “K 2”
  Note
The upper section of bushing cannot be removed or installed alone. It is always removed or installed together with lower section of bushing and »small« engagement lever.
Observe the following when installing a new engaging lever »K2«:
 

Adjusting clutch engagement

The new engaging lever »K2« with upper and lower section of guide sleeve will be delivered in transport position -illustration- and must be set to installation position prior to installation.
Setting engaging lever »K2« to installation position:
 

Adjusting clutch engagement

–  Hold upper section of guide sleeve with one hand. With the other hand turn the lower section of guide sleeve in direction of arrow until the sleeve moves freely.
  Note
Apply high force to hold both sections, as this is necessary for turning the lower section of the guide sleeve.
 

Adjusting clutch engagement

If the engaging lever is in installation position, the holes of the lower section of guide sleeve are at right angles to the engaging lever. The sleeve moves freely.
Continuation for all:
 

Adjusting clutch engagement

–  Install »small« engagement lever together with upper and lower section of bushing. Insert and tighten new bolts.
Specified torques: → Item
 

Adjusting clutch engagement

–  Insert »small« engagement bearing without shim.
  Caution
Risk of false measurements.
Do not insert any shim!
 

Adjusting clutch engagement

Small engagement bearing only fits in one position due to 8 grooves.
–  By turning, check whether small engagement bearing has been installed correctly and that grooves are seated correctly.
 

Adjusting clutch engagement

–  Place end gauge -T10466- on small engagement bearing. Flat side faces upwards.
–  To ensure that end gauge -T10466- sits properly on engagement bearing, press down and turn end gauge.
Engagement bearing will turn with end gauge -T10466-.
 

Adjusting clutch engagement

–  Place digital 300 mm depth gauge -VAS 6594- on top of ruler and position depth gauge rod on outer input shaft.
Ruler -T40100- is lying upwards across end of shaft on gearbox flange.
  Caution
Risk of false measurements.
The ruler -T40100- should remain in this position for the following measurements. Do not turn over, do not remove.
–  Set depth gauge to “0”.
 

Adjusting clutch engagement

–  Position depth gauge rod on end gauge -T10466-, as show in diagram.
–  In this position, determine dimension “A 2a” to end gauge -T10466-.
Example: Dimension “A 2a” = 4.79 mm
 

Adjusting clutch engagement

–  In the opposite position, determine dimension “A 2b” to end gauge -T10466-.
Example: Dimension “A 2b” = 4.75 mm
–  Calculate mean value from dimension “A 2a” and “A 2b”.
   Formula:
A 2a + A 2b
2
Example:
4.79 + 4.75
2
= 4.77 mm
Result: Dimension “A 2” = 4.77 mm
7th step: Calculate height tolerance of clutch engagement bearing “K 2”
  Note
On the basis of dimension “A 2” and dimension “B”, the height tolerance of the engagement bearing for clutch “K 2” is now calculated according to the following calculus.
 

Adjusting clutch engagement

  Dimension “A 2”
Dimension “B”
= Actual height tolerance of clutch engagement bearing “K 2”
 
Example:
4.77 mm – 2.60 mm = 2.17 mm
Result: Height tolerance of clutch engagement bearing “K 2” = 2.17 mm
   
8th step: Determine clutch tolerance of clutch “K 2”
–  Read clutch tolerance value from new clutch.
Example: Read off clutch tolerance value on clutch “K 2 = – 0.2”, as shown in illustration.
Result: Clutch tolerance of clutch “K 2” = – 0.20 mm.
9th step: Determine thickness of shim “SK 2”
  Note
On the basis of the clutch tolerance “K 2”, the thickness of shim “SK 2” is now calculated according to the following calculus.
 

Adjusting clutch engagement

  Height tolerance of engagement bearing “K 2”
–/+ Clutch tolerance of clutch “K 2”
= Calculated thickness of shim “SK 2”
 
Example:
2.17 mm – 0.20 mm = 1.97 mm
Result: Calculated thickness of shim “SK 2” = 1.97 mm
–  Select required shim with help of table below and have it ready for installation.
   
Calculated thickness of shim mm Available shims Thickness in mm Part number of shim
0.31 … 0.90 0.80 WHT 005 518
0.91 … 1.10 1.00 WHT 005 518 A
1.11 … 1.30 1.20 WHT 005 518 B
1.31 … 1.50 1.40 WHT 005 518 C
1.51 … 1.70 1.60 WHT 005 518 D
1.71 … 1.90 1.80 WHT 005 518 E
1.91 … 2.10 2.00 WHT 005 518 F
2.11 … 2.30 2.20 WHT 005 518 G
2.31 … 2.50 2.40 WHT 005 518 H
2.51 … 2.70 2.60 WHT 005 518 J
2.71 … 3.30 2.80 WHT 005 518 K
 
Example:
Result: calculated thickness of shim “SK 2” = 1.97 mm
Chosen shim thickness = 2.00 mm
  Caution
The clutch can be damaged.
Install only this shim later when required.
The adjusting work has now been completed and the »small« engagement lever has already been installed.
–  Install dual clutch → Chapter.
   
Removing and installing clutch engagement
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