BGS technic 8320 User manual

BGS technic KG
Bandwirkerstr. 3
D-42929 Wermelskirchen
Tel.: [phone]
Fax.: [phone]
[e-mail]
www.bgstechnic.com
© BGS technic KG, Copying and further use not allowed
BGS 8320
Duplex Clutch Repair Kit for
VAG DSG Transmissions
TOOLS
1 Thrust piece,
to be used as OEM T10376
2 Slip gauge,
to be used as OEM T10374
3 Puller,
to be used as OEM T10373
4 Support bridge,
to be used as OEM T10323
INTENDED USE
This repair kit is needed for servicing clutches in the following car types:
VW Golf (since 2004), Golf Plus (since 2005) with 7-drive transmission (Code 0AM), Audi A3 (since
2004) with 7-drive transmission (Code 0AM) and Touareg (since 2003) with 6-drive transmission
(Code 08D).
SAFETY INFORMATIONS
•Do not use the tool if parts are missing or damaged.
•Use the tool for the intended purpose only.
•Never place the tool on the vehicle battery. There is a risk of a short circuit.
•Be careful when working with the engine running. Loose clothing, tools and other objects can
be caught by rotating parts and cause serious injury.
•Keep children and other unauthorized persons away from the work area.
•Do not allow children to play with the tool or its packaging.
•Be careful when working on hot engines because of the risk of burn injuries.
•If you remove the ignition key before repairing, you can prevent the engine from being started
accidentally and resulting in engine damage.
•This manual serves as a brief guide and does not replace a workshop manual. Always refer to
the vehicle-specific service literature, particularly the technical data such as torque values and
instructions for disassembly/assembly, etc..

BGS technic KG
Bandwirkerstr. 3
D-42929 Wermelskirchen
Tel.: [phone]
Fax.: [phone]
[e-mail]
www.bgstechnic.com
© BGS technic KG, Copying and further use not allowed
INSTRUCTION
Support bridge
Remove clutch hub.
Disassemble lock ring of the clutch (this might be difficult
because the clutch is under strong tension
Release the clutch by using the support bridge as shown in
the picture.
Puller
After the disassembly of the lock ring you can attach the
puller as shown and disassemble the clutch by turning the
puller spindle.
Slip gauge
You can adjust the position of the engaging bearings by
using the slip gauge. Use a depth gauge for measuring. For
exact dimensions and detailed information about how to do
it, consult the manufacturer’s handbook.
ADJUSTMENT
Adjust position of the engaging bearings.
It is necessary to adjust the position of the engaging bearings after replacing the engaging bearings,
the starting lever or the starting lever seating.
The locating face (gearbox/motor) has to be completely level in order to make sure for a good rest for
the ruler.

BGS technic KG
Bandwirkerstr. 3
D-42929 Wermelskirchen
Tel.: [phone]
Fax.: [phone]
[e-mail]
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Installation of the two starting levers
and their engaging bearings.
Place the 1.4 millimeter thick dial on each
bearing (arrow).
As there are 2 clutches, there will be 2 steps of adjusting
them.
You will be doing several measurements while carrying out
this operation.
Each measurement requires different preparations and a few
simple calculations.
Please strictly follow these operating sequences.
You will start with the big engaging bearing for clutch 1 (K1).
First measurement for (K1)
Remove the small engaging bearing with the 1.4 millimeter
thick dial.
Place the slip gauge on the big engaging bearing.
Exert some pressure on the slip gauge and rotate it to make
sure for the correct seating of the slip gauge on the bearing.
Place the ruler on the gearbox flange and use the depth
gauge for your measurement of the depth down to the gear
shaft.
Note down the measured value as (B).
Example: B= 62.3 mm
Slip gauge
Slip gauge

BGS technic KG
Bandwirkerstr. 3
D-42929 Wermelskirchen
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Second measurement for (K1)
Measure the distance from the ruler down to the slip gauge.
Make this measurement as precisely as possible by taking
readings from two opposite positions.
Thus, the determined value will be more precise, and any
inaccuracy caused by a „tilting“ on the engaging bearing will
be minimized.
Take the mean value of both measurements on the slip
gauge. Note down the value as (A).
Example: A= 64 mm
Calculate the difference of the 2 values
A - B = ?
In our example the calculation is as follows:
64.0 mm – 62.3 mm = 1.7 mm
Refer to the below table for the required thickness of the dial.
Your reading for bearing K1
from
to
required dial
0,71 mm
0,9 mm
0,8 mm
0,91 mm
1,1 mm
1,0 mm
1,11 mm
1,3 mm
1,2 mm
1,31 mm
1,5 mm
1,4 mm
1,51 mm
1,7 mm
1,6 mm
1,71 mm
1,9 mm
1,8 mm
1,91 mm
2,1 mm
2,0 mm
2,11 mm
2,3 mm
2,2 mm
2,31 mm
2,5 mm
2,4 mm
2,51 mm
2,7 mm
2,6 mm
2,71 mm
2,9 mm
2,8 mm
In our example we need a 1.6 mm thick dial.
Never use more than a single dial. Never place 2 dials on top of each other to reach the required
thickness.
Following this procedure, the position of the bearing K1 will be adjusted.
Remove again the bigger starting lever for the subsequent
(K2) measurement.
Slip gauge
Slip gauge

BGS technic KG
Bandwirkerstr. 3
D-42929 Wermelskirchen
Tel.: [phone]
Fax.: [phone]
[e-mail]
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First measurement for (K2)
Use a 1.4 mm thick dial.
Install the small bearing only with a 1.4 mm thick dial.
The small engaging bearing will only lock into one position
because of the 4 grooves.
Rotate to check that the bearing is correctly installed with the
grooves in their right position.
Place the slip gauge onto the small bearing.
Slip gauge

BGS technic KG
Bandwirkerstr. 3
D-42929 Wermelskirchen
Tel.: [phone]
Fax.: [phone]
[e-mail]
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Use the depth gauge to measure down to the gear shaft.
Note down this value as (B).
Example: B = 62.3 millimeters
Second measurement for (K2)
Measure the distance from the ruler down to the slip gauge.
Make this measurement as precisely as possible by taking
readings from two opposite positions.
Thus, the determined value will be more precise, and any
inaccuracy caused by a „tilting“ on the engaging bearing will
be minimized.
Take the mean value of both measurements on the slip
gauge. Note down the value as (A).
Example: A= 63.5 mm
Calculate the difference of the 2 values
A - B = ?
In our example the calculation is as follows:
63.5 mm – 62.3 mm = 1.2 mm
Refer to the below table for the required thickness of the dial.
Your reading for the bearing K2
from
to
required dial
0,71 mm
0,9 mm
0,8 mm
0,91 mm
1,1 mm
1,0 mm
1,11 mm
1,3 mm
1,2 mm
1,31 mm
1,5 mm
1,4 mm
1,51 mm
1,7 mm
1,6 mm
1,71 mm
1,9 mm
1,8 mm
1,91 mm
2,1 mm
2,0 mm
2,11 mm
2,3 mm
2,2 mm
2,31 mm
2,5 mm
2,4 mm
2,51 mm
2,7 mm
2,6 mm
2,71 mm
2,9 mm
2,8 mm
In our example we need a 1.2 mm thick dial.
Never use more than a single dial. Never place 2 dials on top of each other to reach the required
thickness.
Following this procedure, the position of the bearing K2 will be adjusted.
Slip gauge
Slip gauge
Slip gauge