Clutch "D/G" With Freewheel, Disassembling and Assembling

Clutch "D/G" with freewheel, disassembling and assembling - 5 Spd. A/T 01V Front and All Wheel Drive

Disassembling

^ Clutch "D" faces upward.

- Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".
- Twist cylinder "D/G".

^ Clutch "G" faces upward (plate spring is visible).

- Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".

- Place cylinder "D/G" on thrust piece 3301/4 under shop press.
- Press plate spring down under shop press using installation bracket T10289.
- Remove circlip - 1 -, thrust washer and plate spring.
- Release shop press.

CAUTION:
Wear eye protection.

- Carefully press piston "G" out of cylinder "D/G" with compressed air.

- Press freewheel inner race - 2 - out of cylinder "D/G" - 1 - - arrow -, loosen with light taps using a plastic hammer if necessary.
- Remove cylinder "D/G" from freewheel.
- Twist cylinder "D/G".

^ Cylinder "D" faces upward.

CAUTION:
Wear eye protection.

- Carefully press piston "D" out of cylinder "D/G" with compressed air.

- Disassemble freewheel:

6 - Plate spring
5 - Holding plate
4 - Freewheel with freewheel housing
3 - Rectangular rings
2 - O-rings
1 - Freewheel inner race

Assembling

CAUTION:
Before assembling, check components of freewheel, clutch "D" or clutch "G" for wear and damage.

- Replace O-rings - 2 - and - 4 - for piston "D" - 3 -.
- Press piston "D" - 3 - into cylinder "D/G" - 1 - as far as stop.

- Insert waved washer - 2 - into cylinder "D/G" - 1 -.
- Install outer plate - 3 - and coated plate - 4 - alternately.
- Install thick outer plate - 5 -.

Note:
^ Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

- Insert circlip - 6 -.

Adjust clutch "D" air gap

- Place clutch "D/G" on pre-tensioning tool T10285

^ Clutch "D" faces upward.

- Place plate T10293 on outer clutch disc "D".

^ Plate must not touch circlip all around.

- Insert pressure unit T10285/1 with centering pin into bore of plate.
- Align clutch "D/G" on plate of pre-tensioning tool.

^ The pressure unit must be centrally positioned under spindle thrust piece.

- Turn spindle of pre-tensioning tool downward.

^ The markings at inspection hole of the pressure unit must align - arrow -.

- Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G", as depicted in illustration.
- Apply measuring tongue on outer plate and note measuring value.
- Mark contact point on cylinder "D/G".
- Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.
- Average over 3 measured values under load.
- Release spindle and remove plate.
- Reach with both hands into clutch "D" and pull plate pack upward until stop.
- When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer disc (2nd technician required) at one of marked points.
- Repeat measurement at 2 other marked points of outer plate.
- Average over 3 measured values when plate pack is pulled up.
- Determine air gap on basis of the following calculations:

- Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "D" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "D" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained:

- Determine new circlip - 1 - according to the following table.

Note:
^ Disregard - 2 -.

^ Air gap too small: Install respectively thinner circlip.
^ Air gap too large: Install respectively thicker circlip.

- Check air gap of circlip again after inserting.

- After having determined correct circlip, remove circlip - 1 - and remove plate pack - 2 from cylinder "D/G" again.

- Replace O-rings - 2 - and rectangular rings - 3 - on freewheel inner race - 1 -.

4 - Freewheel with freewheel housing
5 - Holding plate
6 - Plate spring

- Before inserting, thinly coat O-rings and rectangular rings with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
- Make sure that rectangular rings are fully seated all around in freewheel inner race grooves.

- Insert freewheel inner race - 2 - with freewheel housing until stop into freewheel - 1 - using turning motions in clockwise direction - arrows -.

- Lay cylinder "D/G" - 1 - on 2 wood blocks in height of approx. 40 mm.

^ Cylinder "D" faces upward.

- Insert dished washer - 2 - and holding plate - 3 - into cylinder "D/G".

^ Tabs on holding plate face cylinder "D/G".

- Grasp freewheel - 4 - so that the freewheel inner race can no longer slip out and press inner race splines into splines of cylinder "D/G".

- Twist cylinder "D/G" - 1 -, while doing so secure freewheel inner race against slipping out.

^ Cylinder "G" faces upward.

- Place cylinder "D/G" on thrust piece 3301/4.
- Replace O-rings - 2 - and - 4 - for piston "G" - 3 -.
- Press piston "G" - 3 - into cylinder "D/G" until stop.
- Place dished washer - 5 - and thrust washer - 6 -.

^ Teeth of thrust washer must engage into splines of freewheel inner race.

7 - Circlip

- Place cylinder "D/G" on thrust piece 3301/4 under shop press.
- Press plate spring down under shop press using installation bracket T10289.
- Push thrust washer fully downward and insert circlip - 1 -.
- Make sure that circlip is seated evenly all around in groove of freewheel inner race, if necessary, press circlip into groove all around using screwdriver.
- Release shop press.
- Press plate spring down again to check if freewheel is inserted correctly.

^ Thrust washer - 6 - in previous illustration "A37-10345" must be able to move.

- Place clutch "D/G" on pre-tensioning tool T10285
- Place plate T10292 on outer clutch disc "G"

^ Plate must not touch circlip all around.

- Insert pressure unit T10285/1 with centering pin into bore of plate.
- Align clutch "D/G" on plate of pre-tensioning tool.

^ The pressure unit must be centrally positioned under spindle thrust piece.

- Turn spindle of pre-tensioning tool downward.

^ The markings at inspection hole of the pressure unit must align - arrow -.

- Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G", as depicted in illustration.
- Apply measuring tongue on outer plate and note measuring value.
- Mark contact point on cylinder "D/G".
- Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.
- Average over 3 measured values under load.
- Release spindle and remove plate.

- Reach with both hands into clutch "G" and pull plate pack upward until stop.
- When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer disc (2nd technician required) at one of the marked points.
- Repeat measurement at 2 other marked points of outer plate.
- Average over 3 measured values when plate pack is pulled up.
- Determine air gap on the basis of the following calculations:

- Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "G" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "G" air gap - Automatic Transmission 01V All Wheel Drive

- Twist clutch "D/G".

^ Clutch "D" faces upward.

- Install plates for clutch "D" with newly determined circlip as follows: