Dismantling and assembling clutch "C": VW Passat B5 / Phaeton

🧭 Before you start

Fits: VW Passat B5 (3B), VW Phaeton (3D)

Don't miss

• Ensure that the rounded edges of the thick outer plate face towards friction plate (4), not towards retaining ring (6). This improves the contact surface for the retaining ring.
• Mark contact point on outer plate carrier "“C”".
• Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points.
• (Item 2) can be disregarded.

📋 Procedure

1. Turn ATF supply unit upside down.
2. Remove retaining ring (1) and remove set of plates (2) from cylinder "“C”".
3. Press down dished spring using workshop press with assembly jig T10289.
4. Remove split retaining ring (1).
5. Release workshop press.

6. Remove dished spring (5).
7. ⚠ Wear eye protection. — Carefully press piston "“C”" out of ATF supply unit by applying compressed air.
8. ⚠ Before assembly, check the components of clutch "“C”" for traces of wear and damage . — Renew O-rings (2) and (4) for piston "“C”"(item 3).
9. Insert piston "“C”"(item 3) into ATF supply unit (item 1) as far as stop.
10. Fit dished spring (5).
11. Press down dished spring using workshop press with assembly jig T10289.
12. Insert split retaining ring (1).
13. Release workshop press.
14. Insert corrugated spring (2) into cylinder "“B”"(item 1).
15. Fit outer plates (3) and friction plates (4) alternately.
16. Insert thick outer plate (5). [Note: Ensure that the rounded edges of the thick outer plate face towards friction plate (4), not towards retaining ring (6). This improves the contact surface for the retaining ring.]
17. Insert retaining ring (6).
18. Clamp wide support leg of compressor tool T10285 in vice.
19. Place ATF supply unit on compressor tool.
20. Position holding plate T10295 on outer plate of clutch "“C”".
21. Fit centring pin of thrust piece T10285/1 into drilling in plate.
22. Bring ATF supply unit into correct position on holding plate of compressor tool.
23. Turn spindle of compressor tool downwards.
24. Apply digital depth gaugeVAS 6087 to upper rim of outer plate carrier "“C”" as shown in illustration.
25. Bring measuring tip into contact with outer plate and note value obtained.
26. Mark contact point on outer plate carrier "“C”".
27. Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points.
28. Determine average value from the three measurements under load.
29. Release spindle and remove holding plate.
30. Use both hands to pull set of plates upwards as far as possible in clutch "“C”".
31. With set of plates pulled up to stop, measure distance between upper edge of outer plate carrier "“C”" and outer plate at one of the marked points (assistance of second mechanic required).
32. Repeat measurement at the two remaining markings on the outer plate.
33. Determine average value from the three measurements with set of plates pulled to stop.
34. Determine clearance using the following formula:
35. Subtract mean value of measurement with set of plates pulled up to stop from mean value of measurements under load.
36. Determine new retaining ring (1) according to following table. [Note: (Item 2) can be disregarded.]
37. Check clearance again after inserting retaining ring.

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