Installing dual clutch, gearbox date from 06.2011 — VW

🧭 Before you start

Fits: VW Passat CC (357, 2008–2012), VW Polo 6R (2009–2014), VW Touran I (1T, 2003–2015), VW Golf V / Jetta (1K, 2003–2009), VW Passat B6 (3C, 2005–2010), VW Golf VI (5K, 2008–2013); platform codes 5M1, 1F7, 137, 521

• Special tools named: T10373, T10356/5, puller

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• The large shim is inserted into the large engagement bearing, with the hemispherical side of the shim facing downwards.The small shim goes under the small engagement bearing. Therefore, insert shim first.
• Bolts (A), secure with nut as required.
• If the retaining ring cannot be inserted, the clutch has not been pressed in onto its limit stop.
• By pressing on, the clutch sits at the bottom against the limit stop on the input shaft. This is not the optimum position.Clutch should only be pulled up far enough for it to contact retaining ring.
• For some gearboxes the breather cap on the mechatronic unit is destroyed during removal and must be renewed. — Dispose of excess shims.

📋 Procedure

1. ⚠ If the dual clutch is renewed, the following components must also be renewed:Both engaging levers with engagement bearing.Ball-head pin for engaging lever "“K 2”".Shims for engagement bearing.The hinge mounting cannot be removed.After the dual clutch and corresponding components have been renewed, the position of the engagement bearings for "“K 1 and K 2”" must always be readjusted . — Install »small« engagement lever together with upper and lower parts of guide sleeve. Insert and tighten new bolts.
2. ⚠ Risk of damage to clutch and other components!The positions of the engagement bearings must be set correctly.Adjustment can only be carried out before the clutch is installed.Do not continue with assembly until the setting is correct!If no new parts have been installed, insert removed shims.For adjustment, only one shim per engagement bearing may be installed.Clutch parts must be free of oil and grease. — Insert »large« engagement lever with measured shims for "“K 1”" and "“K 2”" and with small engagement bearing. [Note: The large shim is inserted into the large engagement bearing, with the hemispherical side of the shim facing downwards.The small shim goes under the small engagement bearing. Therefore, insert shim first.]
3. By turning, check that parts have been installed correctly and that grooves are seated correctly.
4. Check both engaging levers are seated correctly.
5. Turn back spindle of puller T10373.

6. ⚠ Risk of damage from clutch adjustment device.The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Do not allow clutch to fall into gearbox during installation. — Install clutch with puller T10373 in gearbox, as shown in diagram.
7. Position support bracket T10323 parallel to gearbox flange as shown in illustration.
8. If necessary, balance out gaps using T10356/5 from assembly tool T10356, for example.
9. Screw in bolts (A) hand-tight. [Note: Bolts (A), secure with nut as required.]
10. Press on clutch as far as it will go. [Note: Place a hand on the clutch when pressing it on. A slight »rattling« will be felt. Rattling indicates that the clutch is being pressed onto its press seat. This also enables detection of the limit stop once the clutch has been seated correctly.]
11. Take hold of new retaining ring with retaining ring pliers, as shown in the illustration.
12. Inserting retaining ring (arrow). [Note: If the retaining ring cannot be inserted, the clutch has not been pressed in onto its limit stop.]
13. To ensure that the clutch reaches its operating position right from this stage, turn it against puller T10373(arrow) by hand without using any other tools. [Note: By pressing on, the clutch sits at the bottom against the limit stop on the input shaft. This is not the optimum position.Clutch should only be pulled up far enough for it to contact retaining ring.] [Note: Only turn by hand. In this way, clutch slides against retaining ring. Do not use any other tool.]
14. Insert hub.
15. Insert retaining ring (arrow) of hub.
16. Turn clutch by hand. It should be possible to turn it without difficulty. [Note: If the clutch is difficult to turn or if the clutch lining is being rubbed hard, remove clutch again .Check installation position of shims (arrows).The shims must be properly seated and undamaged .A mathematical error could have been made. Check measurements again If no error has been made, the clutch may have been moved out of position due to transport/assembly and a new clutch now has to be installed. The position of the engagement bearings must then be readjusted .]
17. Remove two plugs and put breather caps (arrows)on.
18. ⚠ For some gearboxes the breather cap on the mechatronic unit is destroyed during removal and must be renewed. — Dispose of excess shims.
19. After installation of gearbox, perform Complete reset by means of Guided functions.

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