Adjusting clutch engagement, gearboxes up to 05.2011 — VW

🧭 Before you start

Fits: VW Golf Cabriolet (517, 2011–2016), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014), VW CC (358, 2012–2017)

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• Risk of damage to clutch and other components!Retainer for engaging lever and entire mechanism of engagement bearing must be dry and free of oil or grease. — Insert retainer for engaging lever.
• Only a few, »older« gearboxes do not have a clip.
• Do not measure on retaining ring joint. The retaining ring could be pushed away and falsify the reading.
• Risk of false measurements.Do not insert any shim! — Place end gauge T10374 on large engagement bearing with large opening upwards.
• To ensure that end gauge T10374 sits properly on engagement bearing, press down and turn end gauge.

📋 Procedure

1. ⚠ Risk of damage to clutch and other components!Retainer for engaging lever and entire mechanism of engagement bearing must be dry and free of oil or grease. — Insert retainer for engaging lever.
2. Fit small engaging lever with clip and secure with 2 new bolts. Specified torque: [Note: Only a few, »older« gearboxes do not have a clip.]
3. Insert large engaging lever.
4. Check both engaging levers are seated correctly.
5. Install old retaining ring of outer input shaft.

6. Place ruler T40100 upwards across end of shaft onto gearbox flange.
7. ⚠ Risk of false measurements.The ruler T40100 should remain in this position for the following measurements. Do not turn over, do not remove. — Place digital 300 mm depth gaugeVAS 6594 on top of ruler T40100 and position depth gauge rod on outer input shaft.
8. Set depth gauge to "“0”".
9. Position depth gauge rod on retaining ring, as show in diagram.
10. In this position, determine dimension "“B"1” to retaining ring.
11. 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.]
12. Calculate mean value from dimension "“B"1” and "“B"2”.
13. Remove and dispose of retaining ring.
14. ⚠ Risk of false measurements.Do not insert any shim! — Place end gauge T10374 on large engagement bearing with large opening upwards.
15. To ensure that end gauge T10374 sits properly on engagement bearing, press down and turn end gauge.
16. Place digital 300 mm depth gaugeVAS 6594 on top of ruler and 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 T10374, as show in diagram.
19. In this position, determine dimension "“A 1"a” to end gauge T10374.
20. In the opposite position, determine dimension "“A 1"b” to end gauge T10374.
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 actual installation depth of the clutch engagement bearing "“K 1”" is now calculated based on the following calculus.] [Note: With the actual value and specification for the engagement bearing installation depth, the clearance of clutch "“K 1”" is now determined using the following calculus.]
22. Take clutch tolerance value from new clutch. [Note: On the basis of the clearance value and clutch tolerance "“K 1”", the thickness of shim "“SK 1”" is now calculated using the following calculus.]
23. From the shims supplied, measure the required shim and have it ready for installation.
24. ⚠ Risk of damage to gearboxMark shim "“SK 1”" and have it ready for assembly.For adjustment, only this shim "“SK 1”" may be inserted. — Only insert small engagement bearing.
25. By turning (arrows), check whether small engagement bearing is properly installed and that grooves are seated correctly.
26. ⚠ Risk of false measurements.Do not insert any shim! — Place end gauge T10374 on small engagement bearing with large opening upwards.
27. Place digital 300 mm depth gaugeVAS 6594 on top of ruler and position depth gauge rod on outer input shaft.
28. ⚠ 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”".
29. Position depth gauge rod on end gauge T10374, as show in diagram.
30. In this position, determine dimension "“A 2"a” to end gauge T10374.
31. In the opposite position, determine dimension "“A 2"b” to end gauge T10374.
32. Calculate mean value from dimension "“A 2"a” and "“A 2"b”. [Note: On the basis of dimension "“A 2”" and dimension "“B”", the actual installation depth of the clutch engagement bearing "“K 2”" is now calculated based on the following calculus.] [Note: With the actual value and specification for the engagement bearing installation depth, the clearance of clutch "“K 2”" is now determined using the following calculus.]
33. Take clutch tolerance value from new clutch. [Note: On the basis of the clearance value and clutch tolerance "“K 2”", the thickness of shim "“SK 2”" is now calculated using the following calculus.]
34. From the shims supplied, measure the required shim and have it ready for installation.
35. ⚠ Risk of damage to gearboxMark shim "“SK 2”" and have it ready for assembly.For adjustment, only this shim "“SK 2”" may be inserted. — Install dual clutch .

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