TL100090 - APR DSG Clutch Instructions

Removal

1. Drain transmission fluid

2. Remove the transmission from the vehicle.

3. Position the transmission vertically on a work table.

4. Replace the transmission filter (tightening torque is 20Nm).

5. Using zipper bag provided, presoak K1 and K2 frictions in new DSG fluid for 30 minutes

prior to installation.

6. Remove the large outer clutch end cover circlip.

7. Remove clutch end cover using a screw driver. Access the cover through the starter

installation opening.

8. Place the clutch end cover down on the PTFE Seal Installation Tool. VW Special Tool

T10302 / ES#2523316.

9. Make an alignment mark on the drive plate cover and clutch basket. NOTE: A factory white

mark may be visible.

10. Remove the clutch basket drive plate outer circlip.

11. Remove the drive plate.

12. Remove the oil pump drive shaft.

13. Carefully remove the circlip from the center of the assembly. Do not over extend it. Only

apply enough outward force to remove the circlip.

14. Remove the clutch basket from the transmission.

15. Using a flat screwdriver, remove the outer (K1) circlip.

16. Turn the clutch basket upside down to remove the K1 / K2 drums and K1 clutch pack.

17. Turn the clutch basket right side up.

18. Using a flat screwdriver, remove the inner (K2) circlip.

19. Turn the clutch basket upside down again to remove the K2 clutch pack.

20. Turn the clutch basket right side up again.

Page 2  

 

Installation

1. Install the K2 clutch pack starting with a steel.

2. Alternate between a friction and a steel until all are installed. NOTE: Make sure "TOP" is

showing when installing each K2 friction.

3. Install the K2 piston top plate.

4. Using a small flat screwdriver, align the teeth of the frictions and install the K2 drum. Lightly

rotate it from side to side until the drum is completely seated.

5. Install the circlip for the K2 clutch pack.

6. Install the K1 clutch pack starting with a steel.

7. Alternate between a friction and a steel until all are installed. Note K1 frictions can be

installed in either direction.

8. Install the K1 piston top plate.

9. Using a small flat screwdriver, align the teeth of the frictions and install the K1 drum. Lightly

rotate it from side to side until the drum is completely seated.

10. Install the circlip for the K1 clutch pack.

11. Install the Clutch Retaining Bar. VW Special Tool T10303 / ES#2748527

12. Reinstall the clutch basket into the transmission.

13. Reinstall the oil pump drive shaft.

14. Carefully reinstall the circlip on the center of the assembly. NOTE: If the basket you are

reinstalling is not the same basket that was removed, see section on "Circlip Selecting".

15. Reinstall drive plate. NOTE: Line up the marks you made during the removal process.

16. Install the drive plate circlip.

17. Remove the Clutch Retaining Bar T10303

18. Reinstall the clutch end cover using PTFE Installation Tool T10302. NOTE: Be careful not to

roll the PTFE seal.

19. Reinstall the large outer clutch end cover circlip.

20. Reinstall the transmission into the vehicle.

21. Prior to starting, fill the transmission with oil. NOTE: Follow the factory filling instructions

carefully.

22. IMPORTANT!!! : Prior to driving, you must reset the DSG Basic Settings using VCDS (Beta

16.6.0 or higher), ErWin, or the VW Factory Scan Tool. If this step is not performed correctly, clutch and or transmission damage may occur.

Page 3  

 

02E DSG Gear Oil Level, Draining, and Filling

Draining 1. Replace DSG Oil Filter. Tightening torque is 20 Nm. 2. Remove drain plug. Allow oil to drain. 3. Remove the spill over tube. Allow oil to drain completely. 4. Reinstall the spill over tube. Tightening torque is 3 Nm. 5. Install the VAS 6262A (or equivalent) fill port to the oil pan.

Filling 1. Wait for transmission to cool completely. 2. Connect VAS 6262A (or equivalent) filling hose to fill port. 3. Fill transmission with 5.5L of DSG Transmission Oil. NOTE: Only approved DSG

transmission oils may be used. Always verify the correct type using ETKA, or the factory repair manual.

4. Start the engine, depress the brake and manually select P, N, R, D, and S at idle. Retain each position for at least 3 seconds.

5. Place the gear selector back into P, continue to allow the engine to idle and raise the vehicle.

6. Using VAGCOM, ErWin, or VW Factory Scan Tool, monitor the gearbox oil temperature. 7. As the temperature of the oil increases, the unnecessary amount of DSG oil will flow out

of the spill over tube and exit the transmission. 8. When the temperature of the DSG oil reaches 35 degrees C, remove the filling device.

NOTE: Oil must be slowly running out. 9. Reinstall the drain plug with a new crush washer. Tightening torque is 45 Nm. NOTE:

The filling procedure must be completed by the time the oil temperature reaches 45 degrees C. If this temperature is exceeded, the gearbox will need to cool completely and the procedure must be repeated

10. Perform DSG Basic Settings using VCDS (Beta 16.6.0 or higher), ErWin, or the VW Factory Scan Tool.

Page 4  

 

DSG Clutch Basket Circlip Selecting

1. Using a veneer caliper, measure, locate, and install the 2.0mm thick circlip from the supplied shim kit onto the input shaft (arrow).

2. Attach the dial indicator holder (VW Special Tool - VW 387) to the transmission flange.

For the 1st measurement, place dial gauge measuring tip on input shaft, as show in the picture below. Set the dial gauge with 2 mm preload to “0”. With both hands, lift and raise the multi-plate clutch all the way up pulling against the circlip. Read and record the measurement (input shaft axial play).

Page 5  

 

3. For the 2nd measurement, place dial gauge measuring tip on inner clutch pack carrier hub, as show in the illustration. NOTE: Measuring tip must not be placed on circlip. Set the dial gauge with 2 mm preload to “0”. With both hands, raise the multi-plate clutch all the way up. Read and record the measurement. The new circlip will be determined using the following formula: Circlip = 2nd Measurement – 1st Measurement + 1.85 (constant value)

4. The new circlips are staggered in 0.1 mm increments. Round to the closest number when

selecting: Up to 0.049 is rounded down, and from 0.05 on is rounded up. Remove the 2mm circlip and install the proper one. If it is determined that the proper circlip should be 2mm, leave the 2mm installed.