8-0117

Self-Adjusting Clutch Cover Installation Instructions:

  • Please note that installing this Dual-clutch (DCT) requires the following specific tool kits for proper installation.
  • Using the correct tool kit ensures a secure and effective fit. To complete the installation correctly and efficiently, ensure that you use the designated toolkit.
  • Failure to use the required tool kit will void the warranty.

Fitment tool kit

Calibration tool kit

Dual-Clutch Transmission (DCT) – Pre-Installation & Installation Guide:

Minimum Fitment Requirement:

This product should only be fitted by a qualified technician. The manufacturer’s service manual must be followed at all times – do not attempt a clutch replacement without the manufacturer’s service manual.

Pre-installation:

  1. Before any disassembly: the mechatronics must be pre-tested and confirmed free of fault codes. This procedure may only be performed using VAG-approved diagnostic software and equipment.
  2. Ensure that the mechatronics fuse is in good condition and correctly rated at 30A.
  3. Check for Leaks: Inspect gearbox and engine for oil leaks – repair before fitting.
  4. Check Mountings: Engine, gearbox, and prop shaft mountings must be in good condition.
  5. Inspect Mechatronics Unit: Check connectors and seals for damage – replace if faulty.
  6. Check Input Shafts: Inspect both primary and secondary input shafts for wear – replace if damaged.
  7. Check Hydraulic Circuits: Inspect clutch actuator hydraulics or concentric slave cylinders – replace worn units with OE parts.
  8. Flywheel Condition: Always replace or machine according to DCT manufacturer’s runout tolerance (max 0.1 mm).
  9. Clean All Surfaces: Remove all dirt/oil from bell housing, flywheel, and pressure plate surfaces.
  10. Replace Seals: Replace crankshaft and input shaft seals to prevent oil contamination.

Installation:

  1. Special Tools Required: Use manufacturer-specified alignment and installation fixtures for clutch packs.
  2. Do Not Force Fit: Align gearbox input shafts precisely with clutch hub splines.
  3. Torque to Spec: Flywheel and clutch bolts must be torqued in sequence to OE spec.
  4. Install Per OEM Procedure: Follow model-specific preload and shim settings for clutch packs.
  5. Avoid Bearing Damage: Do not apply pressure to release bearing contact surfaces.
  6. The DCT is a Self-Adjusting Clutch system. When the old kit is removed, the mechatronics unit remains in the “extended position,” meaning the pushrods will over-extend as it still assumes it is operating a worn clutch.
  7. Before the vehicle is started after fitment, the mechatronic must be programmed to Basic Setting. If the vehicle is started and driven off the lift without performing this procedure, the pushrods in the extended position will de-adjust the kit, and no warranty claim can be submitted.
  8. After coding the Basic Setting, the vehicle can be test driven and adaptation values set. This must only be carried out using VAG-approved diagnostic software.

Flywheel Profile:

  • –

Service Note:

  • 7-speed dual clutch transmissions require special tools and adaptation software.
  • Always follow the manufacturer’s fitment and calibration procedure to prevent premature failure.