Volkswagen Golf Variant, Jetta. Manual - part 4

actuators have been renewed.
♦ Retainer also belongs to actuator.
There is no need to adjust anything if all the named parts have

only been removed and reinstalled.
Conditions:
• Only use tools in perfect condition.
• Contact surface of “gearbox on engine” must be free from “ir‐

regularities”. This guarantees straight edge makes good con‐

tact.

• Mechatronic unit is installed.
Perform the following steps:
Position of engagement bearings is comparable with clutch play

of a manual gearbox. In this 0AM dual clutch gearbox, there are

tolerances in engagement system of gearbox and in gearbox it‐

self. There are also tolerances within the dual clutch. These

tolerances must be considered separately when adjusting.
In the following procedure, you are first shown how to measure

all necessary dimensions “on gearbox”, in order to determine

what is the appropriate shim. Tolerances on gearbox and toler‐

ances in clutch determine thickness of shim.
First find a dimension “B”. This dimensions is required for both

clutches “K 1” and “K 2”.
Then find a dimension “A” for each clutch. The following 2 illus‐

trations show where to measure these dimensions.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

1. Removing and installing the dual clutch    

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Note

Perform the following steps “in sequence” and precisely.

Adjusting:

– Install parts of clutch as far as large engaging lever

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Do not install small engagement bearing, do not insert any shim.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

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It should lie sideways on shaft end.

Note

Ruler -T40100- should remain in this position during subsequent

measurements. Do not turn over, do not remove.

– Place digital depth gauge onto outer input shaft.
– “Zero” depth gauge.

– Measure distance from retaining ring.
– Note down result and call it “B”.
Example: “B” = 2.91 millimetres

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

1. Removing and installing the dual clutch    

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Do not measure on ring joint. This could force ring away at that

point and falsify measuring result.

– Remove retaining ring again.
This ring is not allowed to be installed again!
– Calculate average of both measuring results.
Example:

Dimension “B” = B1+B22 = 2,91+3,02 = 2.96

This dimension “B” is needed in the following calculations.
In the following sample calculations, “B” should be 2.96 mm. The

dimension given for “B” is and example. The value for “B” may be

different in another gearbox.
There are 2 clutches, therefore there are 2 setting procedures to

follow.
Each measurement requires different preparatory measures, as

well as a few calculations. Please comply with the following work‐

ing procedures.
Start by calculating shim for clutch “K 1”.
Do not insert any shim!

– Place gauge block -T10374- on “large” engagement bearing.
– Press once onto gauge block -T10374- whilst turning.
In this way, it is possible to observe how the engagement bearing

turns. This means gauge block -T10374- also “sits” correctly on

bearing.

– Place digital depth gauge “at top” onto outer input shaft.
Ruler -T40100- is already “on its side” on gearbox flange

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

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