The General backstory

German engineering is a fine art of perfection!

The dual clutch gearbox of Audi and VW. A neat little German design and a concept that I am definitely a big fan of, little bit complicated sometimes, but overall a very easy gearbox to remove and even more so to work on, even though you need some Special Tools if you have the know how and knowledge to make your own you'll be okay.

Now what I like about this gearbox is that it is actually a manual gearbox, but at the same time. Its almost like the Ford's DCT 250 I think that is a manual electrically shifting gearbox. In order of what I'm trying to say is that this design of gearbox has all the gears, each one working with a syncro-ring and a shared hub and sleeve, it also has a cluster-shaft or counter-shaft.

All of the fundamentals of a manual gearbox, even its dual clutch system. The "add-on" on this box is that is has a Megatronic attached to it that works with electrical solenoids that push on hydraulic chambers in order to shift the gear forks. I'll share some workings on the megatronic, as well as reinstalling the clutch again, but for now I'm going to show you only the removal of the clutch, my way.

OK so first step is to get the gearbox removed from the car obviously, I did that earlier this week. This car is still a work in progress, still need to do strip and quote on the gearbox, all that nice stuff.

After getting the gearbox well placed and in a comfortable position for me I then removed the first cir-clip a fairly easy one to remove, almost like a spring clip, it just holds the clutch dampener in place

Next I removed the clutch dampener and exposed the main bearing and cir-clip of the clutch, I do find it wise to always get a bucket or something that can hold all of my small parts, you don't want to lose any cir-clips, unless you are certain at a clutch replacement.

That's the main cir-clip and can be a fiery one to remove sometimes. I like to give it a little knock at the end of the clip, just to get in un-bedded again.

Remember that cir-clip must have experienced some what of a force for a long time, as well as the constant heat and cold tempering that little fella everyday. Getting myself a proper tool for the job I removed the clip.

Once the clip is out store it safely in your pan, this is the easiest one to lose it sometimes jumps off the cir-clip pliers and shoots into the air. Who here has struggled removing this type of clip before or even the same one with improper tools before, comment below I'd like to know your experience.

I got myself the claw of death, haha nah I'm fooling, I use this oak here to pull the clutch along with the bearing from the shaft. Please don't attempt to remove any part without removing the cir-clip first, and yes I've seen it before.

After placing my tool correctly and gently into place, giving it a firm pull up wards, I can turn the bolt downward creating tension on the tool against the clutch.

Once in place the proper size spanner is required. When starting the tightening process of the tool you feel see, hear and feel the clutch pulling up as the bearing slides over the shaft. Don't fear, nothing broke yet!
When the clutch is completely removed from the shaft I gently pull up and the clutch came out easy easy.

Once the clutch was safely stored, The forks with the actual releasing bearings also needs removal, the first and biggest release bearing can be easily removed with the hand, and the second and smaller one bolts to the bell-housing with two small T30 bolts.

I in general take my clutch parts outside and give it a good blasting with the air, especially when the clutch can be re-used. Spraying all the stuck clutch dust away. Keep in mind I don't recommend doing this, its not safe at all breathing in those fibers, I wear a proper mask while doing it, and I am fully aware of the dangers.

Once everything was removed from the gearbox, I closed up the gaps and gave this dirty gearbox a good old wash using the pressure washer! It came out perfectly nice with the silver casing looking fresh again.

After removing the clutch I found my co-worker in the kitchen making us a nice brunch meal, with some warthog meat, ahhhh certainly more than delish!!

Now look I know a lot of people will say but "fenack, that's just canned sauce, what you going on about? Let me tell you this is definitely good beyond measurement. It's not like the usual all gold canned tomato, its much better. Its tricky though I think this might be original to our country, so don't even bother go looking out for this at the supermarket.

To everyone who made it this far into my post Thank you for the read and the support.

If you found this entertaining or educational please consider a re-blog and up-vote.

Most of all please leave a input in the comments below, whether is good or bad critic I would like to know, whether its your opinion or your way of doing things in a different manner I would like.

_{Connecting the people of #HIVE across South Africa. #hive}