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: |
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 |
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Not shown: Depth gauge, digital 300 mm -VAS 6594- |
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. |
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Removing and installing ball pin |
– |
Use pliers to remove ball-head pin. |
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– |
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. |
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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. |
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1st step: Determine dimension “B” for clutch “K 1” and “K 2” |
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– |
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. |
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– |
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”. |
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– |
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 |
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– |
Remove retaining ring -arrow-
of outer input shaft and dispose. |
Note
It is not permissible to reuse the retaining ring. |
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2nd step: Determine dimension “A 1” for clutch engagement
bearing “K 1” |
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– |
Insert large engaging lever. |
Caution
Risk of false measurements. |
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– |
Check that engaging lever is seated correctly. |
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– |
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-. |
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– |
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”. |
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– |
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 |
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– |
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”. |
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. |
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Dimension “A 1” |
– |
Dimension “B” |
= |
Actual height tolerance of
clutch engagement bearing “K 1” |
5.02 mm – 2.60 mm = 2.42 mm |
Result: Height tolerance of clutch engagement bearing “K 1”
= 2.42 mm |
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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. |
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Height tolerance of engagement
bearing “K 1” |
–/+ |
Clutch tolerance of clutch “K
1” |
= |
Calculated thickness of shim “SK
1” |
2.42 mm + 0.20 mm = 2.62 mm |
Result: Calculated thickness of shim “SK 1” = 2.62 mm |
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– |
Select required shim from the table with the help of the
part number -magnifying glass- and
have it ready for installation. |
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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 |
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. |
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– |
Remove end gauge -T10466- and large engagement lever again. |
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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«: |
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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: |
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– |
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. |
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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. |
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– |
Install »small« engagement lever
together with upper and lower section of bushing. Insert and
tighten new bolts. |
Specified torques:
→ Item |
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– |
Insert »small« engagement
bearing without shim. |
Caution
Risk of false measurements. |
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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. |
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– |
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-. |
|
|
|
– |
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”. |
|
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|
– |
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 |
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– |
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”. |
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. |
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Dimension “A 2” |
– |
Dimension “B” |
= |
Actual height tolerance of
clutch engagement bearing “K 2” |
4.77 mm – 2.60 mm = 2.17 mm |
Result: Height tolerance of clutch engagement bearing “K 2”
= 2.17 mm |
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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. |
|
|
|
|
Height tolerance of engagement
bearing “K 2” |
–/+ |
Clutch tolerance of clutch “K
2” |
= |
Calculated thickness of shim “SK
2” |
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. |
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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 |
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. |
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Removing
Dual clutch removed
→ Chapter.
–
Remove large engaging lever with small engagement bea ...
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