Volkswagen Golf Variant, Jetta. Manual - part 5

1. Removing and installing the dual clutch    

17

 

This allows the value to be found even more accurately, because

the inaccuracy caused by “tilting” on the engagement bearing is

minimised.
– Calculate average of both measurements onto gauge block -

T10374- .

– Note down this value and call it “A1”.
Example:

Dimension “A1” = 2,61+2,812 = 2.71

Example: “A1” = 2.71 millimetres
Next calculation:
“A1” minus “B” plus height of gauge block -T10374- = Depth of

engagement bearing of clutch 1.
Height of gauge block -T10374- is always the same. It is: 51.81

mm.
Sample calculation:
2.71 mm minus 2.96 mm plus 51.81 mm = 51.56 mm.
You have now calculated value for how deep engagement bear‐

ing is actually seated inside gearbox.
Depth of bearing in each gearbox should be 50.08 millimetres.
Subtract nominal dimension “50.08 millimetres” from this actual

value. This gives result for actual gap of clutch 1.
– Continue the calculation:
Calculated value (in example: 51.56 mm) minus nominal dimen‐

sion = gap of clutch.
Sample calculation:
51.56 mm minus “50.08 millimetres” = gap of clutch 1 = 1.48 mm.
Now tolerances in dual clutch must be introduced into this calcu‐

lation. Procedure for this is very simple:
– Please read off value of clutch tolerance of “new” clutch.
A value between minus 0.40 and plus 0.40 millimetres is provided

with a new clutch.
– Make a note of this value.
Example 1: “- 0.40” is indicated on your clutch.
The previous calculation for “K 1”: “your calculated” gap minus

value of clutch 1 =
1.48 mm minus 0.40 = 1.08 mm.
Example 2: “+ 0.20” is indicated on your clutch.
Then, the last calculation of “K 1” is as follows: 1.48 mm plus 0.20

= 1.68 mm.
– Refer to table to find correct shim and install.

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

18

 

metres)

from

to

 

0.31

0.90

0.8

0.91

1.10

1.0

1.11

1.30

1.2

1.31

1.50

1.4

1.51

1.70

1.6

1.71

1.90

1.8

1.91

2.10

2.0

2.11

2.30

2.2

2.31

2.50

2.4

2.51

2.70

2.6

2.71

3.30

2.8

– From the supplied shims, select the one that is required.

WARNING

Later on, only insert this 1 shim. Not 2 shims.

With this, you have found “correct” shim for “K 1”. Please install

this shim during subsequent clutch installation.
– Continue setting for clutch “K 2”.
Calculate shim for clutch “K 2”.

– Only insert small bearing.
Do not insert any shim!

Small engagement bearing only fits in one position due to 4

grooves.

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

1. Removing and installing the dual clutch    

19

 

– Place gauge block -T10374- on small bearing “with large

opening upwards”.

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

– Measure distance from “shaft end” into gauge block -T10374- .

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

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