Table of contents: Flywheel and dual clutch ↓ Removal and installation the flywheel ↓ Removal and installation a dual… ↓
Flywheel and dual clutch
1. Flywheel.
2. Coupling cover.
3. Bolt.
4. Sealing ring: replace.
5. Double clutch: After replacing the double clutch, the corresponding "Guided Function" should be carried out using a diagnostic tester.
6. Carter KP.
7. Double clutch ball bearing.
8. Retaining ring: for ball bearing; replace.
9. Retaining ring: double clutch; replace.
10. Drive shaft sealing ring.
11. Bolt: replace; 3 pcs. in 4-cylinder engines; 6 pcs. in 6-cylinder engines; 60 Nm.
Torque and sequence, tightening for dual clutch and clutch cover
Tighten the bolts in sequence. "1...5" in 3 stages.
1. Tighten evenly by hand until the bolt head is pressed against the clutch cover.
2. Tighten in 90° increments until the clutch cover is flush with the gearbox housing.
3. Tighten to 8 Nm.
Removal and installation the flywheel
The gearbox is secured to the engine and gearbox retainer "VAS 6095". Remove the left shaft with flange. Secure the puller "T40176" to the flywheel "A" with the nut "B" "arrow".
Rotate the "T40176" puller upward. To prevent the flywheel from tipping over, hold it from below, as shown in the figure. Remove the flywheel without tilting it from the drive shaft "arrow".
Installation
Installation in reverse order, thoroughly clean the gearbox housing in the differential access area "arrow A" and the shaft sealing ring "arrow B". If the shaft sealing ring between the differential and the gearbox housing "arrow B" is damaged, replace it.
Fill the space between the working edge and the shooter's boot halfway with sealant. Clean the drive shaft "arrow". Lubricate the drive shaft splines with a thin layer of clutch driven disc spline grease -G 000 100-.
Carefully, without allowing it to tilt, install the flywheel onto the "arrow" drive shaft. Unscrew the "T40176" puller from the "A" flywheel. Install the left shaft with the flange.
Removal and installation a dual clutch
The gearbox is secured to the engine and gearbox holder "VAS 6095". Remove the flywheel. Drain the ATF. Remove the drive shaft seal using the T20143/2 hook.
Unscrew screws "1...5".
Rotate the gearbox in the VAS 6095 tilter in a vertical plane. Place the "T40123 A/1" sleeve onto the drive shaft. Attach the ATF pump drive puller "T40123 A" to the drive shaft. The "arrow" edge of the ATF pump puller should fit under the "T40123 A/1" bushing. Close the puller and tighten the knurled nut "1" (approx. 20 Nm). Check the tightness of the ATF pump puller on the drive shaft.
Connect the ATF pump puller "T40123 A" to the additional hook "10-222 A/2" and hang it on the "VAS 6100" crane. Carefully remove the dual clutch from the gearbox housing.
Place the double clutch with the cover on a soft surface, avoiding damage to the thin spacer "arrow A".
Remove the "arrow" retaining ring with pliers.
Remove clutch cover "2" from clutch "1".
If the clutch cover does not come off, lightly tap the drive shaft with a plastic mallet while the second mechanic lifts the clutch cover manually. In this case, avoid damaging the thin spacer "arrow A".
Installation
Installation in reverse order. Replace the washer and snap ring. Clean the sealing surface on the clutch housing cover. Turn the rectangular section ring "B" on the hub, make sure it moves freely and check the axial clearance. If the movement of the rectangular ring is difficult, the double clutch cannot be installed. Clean the gearbox housing in the area of the double clutch and the sealing surface. Screw the centering tool "T40199" into the threaded holes of the gearbox housing, as shown in the figure
Check the "arrow" thread in the gearbox for signs of wear.
Wet the seal. the "C" ring and "B" hub of the dual clutch are replaced when changing the ATF oil. Insert the dual clutch into the gearbox housing as shown in the figure, using short turns and longitudinal movements to engage the drive shaft between the ATF pump and the gearbox shafts. The dual clutch is installed correctly when the O-ring on the clutch cover fits snugly against the edge of the gearbox housing. Be careful not to pinch the new O-ring during installation. Strictly observe the order. tightening the dual clutch bolts and clutch cover. Replace the seal. drive shaft ring. Install the flywheel. After installing the transmission, add ATF. After replacing the dual clutch, perform the appropriate "Guided Function" using a diagnostic tester.