Adjusting clutch engagement — AUDI

🧭 Before you start

Fit a new ball-head pin, refit the old retaining ring, lay the ruler across the gearbox flange and measure dimension B at two opposite points. Remove and scrap the retaining ring. Fit the large engaging lever and bearing without a shim and measure A1 to the end gauge at two points; work out the shim from the clutch tolerance. Repeat with the small lever, new bolts and the small bearing for A2, select the second shim, then install the dual clutch with the calculated shims.

Fits: VW Caddy IV (SA, 2015–2020)

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• Keep the engaging lever, retainer and bearing mechanism dry and free of grease.
• Leave the ruler in place for all measurements; do not turn it over or remove it.
• Measure without any shim fitted, then install only the calculated shim.
• Do not measure on the retaining ring joint, and never reuse the retaining ring.
• Fit new bolts on the small engaging lever guide sleeve.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. ⚠ Risk of damage to the clutch and other components.Retainer for engaging lever and entire mechanism of engagement bearing must be dry and free of oil or grease. — Use pliers to remove ball-head pin.
2. Push in »new« ball-head pin by hand, if necessary using a plastic hammer and drift to tap it in slightly. [Note: To avoid damage to ball pin, only tap the drift lightly with the plastic head hammer.]
3. Install previously used retaining ring (arrow) of outer input shaft.
4. Place ruler T40100 upwards across end of shaft onto gearbox flange.
5. ⚠ Risk of false measurements.The ruler T40100 should remain in this position for the following measurements. Do not turn over, do not remove. — Fit digital 300 mm depth gaugeVAS 6594 on top of ruler T40100. Position depth gauge rod on outer input shaft.

6. Set depth gauge to "“0”".
7. Position depth gauge rod on retaining ring, as show in diagram.
8. In this position, determine dimension "“B"1” to retaining ring.
9. In the opposite position, determine dimension "“B"2” to retaining ring. [Note: Do not measure on retaining ring joint. The retaining ring could be pushed away and falsify the reading.]
10. Calculate mean value from dimension "“B"1” and "“B"2”. [Note: If the dual clutch is still installed following this measurement, it must now be removed .]
11. Remove retaining ring (arrow) of outer input shaft and dispose. [Note: It is not permissible to reuse the retaining ring.]
12. Insert large engaging lever.
13. ⚠ Risk of false measurements.Do not insert any shim! — Check that engaging lever is seated correctly.
14. Place end gauge T10466 on large engagement bearing. Flat side faces upwards.
15. To ensure that end gauge T10466 sits properly on engagement bearing, press down and turn end gauge.
16. Fit depth gauge, digital 300 mmVAS 6594 on top of ruler. Position depth gauge rod on outer input shaft.
17. ⚠ 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”".
18. Position depth gauge rod on end gauge T10466, as show in diagram.
19. In this position, determine dimension "“A 1"a” to end gauge T10466.
20. In the opposite position, determine dimension "“A 1"b” to end gauge T10466.
21. Calculate mean value from dimension "“A 1"a” and "“A 1"b”. [Note: On the basis of dimension "“A 1”" and dimension "“B”", the height tolerance of the clutch engagement bearing "“K 1”" is now calculated according to the following calculus.]
22. Take clutch tolerance value from new clutch. [Note: On the basis of the clutch tolerance "“K 1”", the thickness of shim "“SK 1”" is now calculated according to the following method.]
23. Select required shim from the table with the help of the part number (magnifying glass) and have it ready for installation.
24. ⚠ Risk of damage to the clutch.Install only this shim later when required. — Remove end gauge T10466 and large engagement lever again. [Note: The upper section of the guide sleeve cannot be removed or installed alone. It is always removed or installed together with lower section of the guide sleeve and the »small« engaging lever.]
25. 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.]
26. Install »small« engaging lever together with upper and lower section of guide sleeve. Insert and tighten new bolts.
27. Insert »small« engagement bearing without shim.
28. ⚠ Risk of false measurements.Do not insert any shim! — By turning, check whether small engagement bearing has been installed correctly and that grooves are seated correctly.
29. Place end gauge T10466 on small engagement bearing. Flat side faces upwards.
30. To ensure that end gauge T10466 sits properly on engagement bearing, press down and turn end gauge.
31. Fit digital 300 mm depth gaugeVAS 6594 on top of ruler. Position depth gauge rod on outer input shaft.
32. ⚠ 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”".
33. Position depth gauge rod on end gauge T10466, as show in diagram.
34. In this position, determine dimension "“A 2"a” to end gauge T10466.
35. In the opposite position, determine dimension "“A 2"b” to end gauge T10466.
36. Calculate mean value from dimension "“A 2"a” and "“A 2"b”. [Note: On the basis of dimension "“A 2”" and dimension "“B”", the height tolerance of the clutch engagement bearing "“K 2”" is now calculated according to the following method.]
37. Take clutch tolerance value from new clutch. [Note: On the basis of the clutch tolerance "“K 2”", the thickness of shim "“SK 2”" is now calculated according to the following method.]
38. From the shims supplied, measure the required shim and have it ready for installation.
39. ⚠ Risk of damage to the clutch.Install only this shim later when required. — Install dual clutch .

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