Assembling clutch "F": VW Phaeton

🧭 Before you start

Fits: VW Phaeton (3D)

Don't miss

• Mark contact point on cylinder "“F”".
• Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points.
• (Item 2) can be disregarded.

📋 Procedure

1. ⚠ Check the individual components of clutch "“F”" for traces of wear and damage Clutch "C" with sun shaft. — Through gearbox No. 069 312, always renew piston "“F”" with part No. 0 501 208 317 using new version with part No. 0 501 212 967. The part No. is stamped into rubber side of piston.
2. Insert piston "“F”", (item 2) in cylinder "“F”", (item 1).
3. Fit dished spring (3).
4. Compress dished spring under workshop press using assembly bar T10276 and insert split retaining ring.
5. Release workshop press.

6. Fit corrugated spring (2) into cylinder "“F”", (item 1).
7. Fit outer plates (3) and friction plates (4) alternately.
8. Insert thick outer plate (5).
9. Insert retaining ring (6).
10. Set cylinder "“F”" on compressor tool T10285.
11. Position holding plate T10280 onto outer plate of clutch "“F”".
12. Fit centring pin of thrust piece T10285/1 into drilling in plate.
13. Bring cylinder "“F”" into correct position on holding plate of compressor tool.
14. Turn spindle of compressor tool downwards.
15. Position digital depth gaugeVAS 6087 on upper edge of cylinder "“F”" as shown in figure.
16. Bring measuring tip into contact with outer plate and note value obtained.
17. Mark contact point on cylinder "“F”".
18. Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points.
19. Determine average value from the three measurements under load.
20. Release spindle and remove holding plate.
21. Use both hands to pull set of plates upwards to stop in clutch "“F”".
22. With set of plates pulled up to stop, measure distance between upper edge of cylinder "“F”" and outer plate at one of the points marked (assistance of second mechanic required).
23. Repeat measurement at the two remaining markings on the outer plate.
24. Determine average value from the three measurements with set of plates pulled to stop.
25. Determine clearance using the following formula:
26. Subtract mean value of measurement with set of plates pulled up to stop from mean value of measurements under load.
27. Determine new retaining ring (1). [Note: (Item 2) can be disregarded.]
28. Check clearance again after inserting retaining ring.
29. Insert 1st gear freewheel (item 2) in clutch "“F”"(item 1), turning clockwise.
30. Insert retaining ring (arrow).

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