Volkswagen Golf Service & Repair Manual: Removing dual clutch

Volkswagen Golf Service & Repair Manual / 7- speed dual clutch gearbox 0CW / Clutch, control / Clutch / Removing dual clutch

Removing dual clutch

Special tools and workshop equipment required

Hook -3438-

Engine bung set -VAS 6122-

Support device -T10323-

-T10356/5- from assembly tool -T10356-

Puller -T10373-

Thrust piece -T10376-

1 x sealing cap -0AM 325 120 A- and 1 x sealing cap -02M 409 120-, as an alternative to engine bung set -VAS 6122-

Prerequisites:

Gearbox removed and secured to engine and gearbox jack → Chapter.

Mechatronic unit for dual clutch gearbox -J743- is built into gearbox.

Caution

Risk of damage to gearbox.

When performing repairs, the breather opening on the mechatronic unit for dual clutch gearbox -J743- (-rear arrow-) and the gearbox breather (-front left arrow-) must be sealed off to avoid loss of fluid.

If any oil escapes from the hydraulic fluid section of the mechatronic unit for dual clutch gearbox -J743-, it is not possible to replenish it or check the level! It is not possible to check the fill level of the hydraulic fluid section of the mechatronic unit for dual clutch gearbox -J743-.

If oil escapes from the gear oil section, it can only be rectified by changing the gear oil. It is not possible to check the fill level.

If the level of oil/fluid is too high or too low in either of the parts, the function of the gearbox will be impaired.

The breather cap on the mechatronic unit is destroyed during removal and must be renewed.

Removing

–	Pull off both breather caps -arrows-.

–	Seal gearbox breather and breather of mechatronic unit for dual clutch gearbox -J743- with clean sealing plugs from engine bung set -VAS 6122- so that no oil can escape.

Note

As an alternative to the engine bung set -VAS 6122- the sealing cap -02M 409 120- can be used to seal the gearbox. The mechatronic unit can be sealed using sealing cap -0AM 325 120 A- as an alternative → Electronic Parts Catalogue (ETKA).

Once the gearbox has been installed in the vehicle, the sealing plugs must be removed and the breather caps reinstalled, or new ones must be fitted if necessary.

Removing dual clutch

–	Turn gearbox on engine and gearbox jack upwards together with clutch.

Note

The clutch is pulled off upwards. Mechatronic unit remains fitted to the gearbox.

Removing dual clutch

–	Remove retaining ring -arrow- for hub.

Removing dual clutch

–	Remove hub with hook -3438- and a screwdriver.

Note

If parts of clutch are renewed, the position of engagement bearings “K 1” and “K 2” must be set later. It is therefore advisable to determine dimension “B” for the measurements now → Chapter.

Removing dual clutch

–	Remove circlip -arrow- for clutch.

If retaining ring cannot be removed:

Note

If the retaining ring cannot be removed it is because the clutch has »clamped« the retaining ring at the bottom.

In this case, push the clutch down slightly (see following description) and release the load on the retaining ring. Never strike the clutch or shaft with a hammer!

Removing dual clutch

–	Position support bracket -T10323- parallel to gearbox flange as shown in illustration.

–	If necessary, balance out gaps using -T10356/5-, for example.

–	Screw in bolts -A- hand-tight.

Note

Bolts -A-, secure with nut as required.

Caution

Risk of damage to clutch and other components!

Push down clutch using only very light force.

–	To press down, turn spindle against thrust piece -T10376-.

Removing dual clutch

–	Remove retaining ring -arrow- for clutch.

Note

It is not permissible to reuse the retaining ring.

Removing dual clutch

Continuation once retaining ring has been removed:

–	Insert puller -T10373- into clutch and bore out clutch.

Removing dual clutch

–	Remove clutch together with puller -T10373-.

Removing dual clutch

Assembly overview - dual clutch

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Installing dual clutch

Special tools and workshop equipment required Support device -T10323- ...

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