Assembly overview - dual clutch — VW

VW
Golf Variant
2007
Golf Variant
2010
Jetta
2005
Jetta
2011
Power transmission
6-speed dual clutch gearbox 02E
Edition
09.2015
Assembly overview - dual clutch
Notes on dual clutch
When carefully considered, the term
»clutch«
is not exactly correct. The term
“dual clutch”
is more appropriate, since each
DSG®
contains at least 2
»clutches«
. In this case, the clutch has 2 sets of plates - making it a
wet clutch
. The outer, larger set of plates is called
“C 1”
(clutch 1). The
“C 1”
selects reverse gear and gears
»1«
,
»3«
and
»5«
. The smaller inner
“C 2”
(clutch 2) selects gears
»2«
,
»4«
and
»6«
.
The assembly of the dual clutch requires special care because all components have been balanced together during manufacture. If parts are rotated relative to each other during assembly, imbalances develop which are detrimental to ease of shifting and service life.
Therefore, genuine clutches are supplied with a built-in retaining ring.
To avoid the risk of parts rotating relative to each other, the method of assembling and installing the clutch in the gearbox housing is shown here. Therefore, you should carefully refer to this description
Chapter
.
Spare parts
Dual clutch with retaining ring
Caution
The drive plate (upper part of the dual clutch) of a new clutch is not secured with the retaining ring. It is merely
»firmly«
seated in the clutch.
The drive plate has to remain engaged between the teeth of the outer plate carrier.
If the drive plate is released, the discs in the dual clutch can shift, as a result of which the clutch may not be correctly configured when it is installed.
Retaining ring
Qty. 10, of varying thickness as appropriate
Thickness of retaining ring must be determined when installing dual clutch
Anchor
.
Clutch end cover
Retaining ring for clutch end cover
Individual parts of the disassembled dual clutch
Caution
This figure is only intended to provide an overview of the components. The dual clutch must not be disassembled at present since all the plates have been balanced relative to each other.
If the drive plate is released, the plates in the dual clutch can shift, as a result of which the clutch may not be correctly configured when it is installed.
Dual clutch/clutch housing
Outer plate carrier
Seal
Qty. 4
Inner plate carrier
Do not remove.
Caution
Under no circumstances raise or remove the inner plate carrier. The plates could turn.
Outer plate
Qty. 4
Inner plate
Qty. 4
Thrust washer
Retaining ring
If retaining ring was removed to insert new plates, it should be renewed with a new, equally thick ring
Retaining ring
Redetermine thickness when installing new dual clutch
Anchor
.
Drive plate
Retaining ring
Renew after removal
Do not install corrugated retaining rings