VW DSG CLUTCH DISSASSEMBLY

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Frank Simmons
5 years ago
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oil breather to prevent oil spilling out.

2 Remove cover in an upwards direction, being

3 Do not touch the seal 4 Remove circlip &

1 IMPORTANT INFORMATION Mar-15 V 3 VW DSG CLUTCH DISSASSEMBLY 1 Turn gearbox on it's end so that clutch cover is facing up. Note: If you have not drained oil - Block off oil breather to prevent oil spilling out. Remove large clutch cover circlip. 2 Remove cover in an upwards direction, being careful not to damage seal. 3 Do not touch the seal 4 Remove circlip & mark the position as shown in the picture. Remove drive plate & set drive plate aside. Page 1

2 5 Remove the center circlip. 6 Hold firmly and pull in an upwards direction. 7 Remove oil pump drive shaft. 8 Remove K1 basket. 9 Remove K2 basket. 10 Remove K2 circlip. 11 Remove K1 circlip. Flip assembly upside down and remove all frictions and steels. Page 2

CLUTCH ASSEMBLY SAME TRANSMISSION 1 Assembling the clutch requires special care as all componenets are calibrated to each other by the manufacturer.

2 It is important to have available a range of housing circlips in order to achieve the clearances / freeplay required. i.e Large Clutch clearance should be between 2.9 and 3.

3 CLUTCH ASSEMBLY SAME TRANSMISSION 1 Assembling the clutch requires special care as all componenets are calibrated to each other by the manufacturer. When assembling; if the position of parts in relation to each other are turned, an imbalance can occur to burden the shifting comfort. 2 It is important to have available a range of housing circlips in order to achieve the clearances / freeplay required. i.e Large Clutch clearance should be between 2.9 and 3.1mm Small Clutch clearance should be between 2.9 and 3.1mm EXAMPLE Clutch Large Clutch Small Stack: 21.1mm Circlip: 2.5mm Plate Top Plate (OE) Clearance: 3.05mm Stack: 20.2mm Circlip: 1.6mm Thickness Plate Thickness 2 Top Plate ( DMS ) 1.5 Clearance: 3.0mm 3 IMPORTANT SOAK FRICTIONS IN OIL PRIOR TO ASSEMBLY. Frictions must rotate in a clockwise direction as shown in this picture. 4 Make sure top plate is installed before circlip DMS TOP PLATE

Page 3 5 In order to achieve freeplay / clerance we pack a selection of circlips in each clutch pack.

LARGE Circlip part #'s SMALL Circlip part #'s VW 02E LGE Cclip 1.3 VW 02E SM Cclip 1.4 VW 02E LGE Cclip 1.5 VW 02E SM Cclip 1.

2 VW 02E LGE Cclip 2.3 VW 02E SM Cclip 2.4 VW 02E LGE Cclip 2.5 6 Measurement proceedure 7 Lift clutch pack and establish clearance.

4 Page 3 5 In order to achieve freeplay / clerance we pack a selection of circlips in each clutch pack. In addition you can order circlips separately using the part numbers below. LARGE Circlip part #'s SMALL Circlip part #'s VW 02E LGE Cclip 1.3 VW 02E SM Cclip 1.4 VW 02E LGE Cclip 1.5 VW 02E SM Cclip 1.6 VW 02E LGE Cclip 1.7 VW 02E SM Cclip 1.8 VW 02E LGE Cclip 1.9 VW 02E SM Cclip 2.0 VW 02E LGE Cclip 2.1 VW 02E SM Cclip 2.2 VW 02E LGE Cclip 2.3 VW 02E SM Cclip 2.4 VW 02E LGE Cclip Measurement proceedure 7 Lift clutch pack and establish clearance. Push caliper down and zero "0" 8 Repeat the measurement procedure for the large clutch. Align friction teeth to allow for K2 and K1 basket to be reinstalled 9 Place DMS VW Clutch Tool in housing 10 Reinstall clutch assembly. Do not let it drop in.

Page 4 11 DMS VW Clutch Tool must be held in place by a second technician when doing this.

NOTE: If fitting into different/new transmission follow "Different Transmission"

Reinstall oil pump drive shaft 13 Fit drive plate (align the marks) Reinstall drive plate

5 Page 4 11 DMS VW Clutch Tool must be held in place by a second technician when doing this. Clutch Tool remains there until the center circlip is installed. 12 Refit center circlip. NOTE: If fitting into different/new transmission follow "Different Transmission" instructions prior to this step. Reinstall oil pump drive shaft 13 Fit drive plate (align the marks) Reinstall drive plate circlip Remove DMS VW Clutch Tool 14 Install seal cover using DMS tool with part # vw 02e seal guide Do not touch the seal Refit the clutch cover circlip

Page 5 1 CLUTCH ASSEMBLY DIFFERENT TRANSMISSION If transferring clutch to another transmission / car, please follow these additional instructions.

Lift clutch upward until it stops and note the measurement result. 2 Second measurement: DMS VW Clutch Tool remains installed! Place gauge plunger onto tab of large clutch pack carrier.

6 Page 5 1 CLUTCH ASSEMBLY DIFFERENT TRANSMISSION If transferring clutch to another transmission / car, please follow these additional instructions. First measurement: DMS VW Clutch Tool remains installed! Fit appropriate dial gauge Place plunger of dial gauge on to transmission input shaft. Set dial gauge to "0" with pre-load. Lift clutch upward until it stops and note the measurement result. 2 Second measurement: DMS VW Clutch Tool remains installed! Place gauge plunger onto tab of large clutch pack carrier. The plunger must not sit on the circlip. Reset dial gauge to "0" with pre-load. Lift clutch upward again to stop and note this result as well. The calculation will be made to determine which of the remaining nine circlips will be finally installed: - For this, use this formula: Second measurement minus first measurement plus 1.85mm = thickness of circlip to be installed. note this result. 3 The nine remaining securing circlips are stepped in 0.1mm increments. Measure all circlips then determine the circlip which matches your result. Remove the 2mm thick circlip & replace with the determined circlip. Install input shaft for transmission oil pump, turn slightly in direction of arrow - when doing this. NOTE: We recommend prior to dissassembly / assembly:- 1. Dealers should carry a range of centre basket circlips in stock to achieve optimum clearance. Please order separately. See page 4 above for range of sizes. 2. Have available the clutch tool kit; part # VW 02E CLUTCH TOOL KIT

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Volkswagen Jetta 2005-> (A5)

Volkswagen Jetta 2005-> (A5) Transmission identification The "6 Spd. Direct Shift Automatic Transmission 02E Front Wheel Drive" is installed in the Jetta 2005. Allocation 00-4, Code letters, assembly allocation,