Clutch "E", Disassembling and Assembling

Clutch "E", disassembling and assembling - 5 Spd. A/T 01V Front and All Wheel Drive

Disassembling





- Place clutch "E" - 1 - in mounting device T10283.





- Remove circlip - 1 - and remove plate pack - 2 - from cylinder "E".





- Press diaphragm plate down under shop press using installation bracket T10276.
- Remove circlip - 1 -.
- Release shop press.





- Remove diaphragm plate - 7 -.
- Remove dished washer - 5 -.
- Twist cylinder "E" -

CAUTION:
Wear eye protection.





- Carefully press piston "E" out of cylinder "E" with compressed air.

Assembling

CAUTION:
Before assembling, check components of clutch "E" for wear and damage.





- Replace O-rings - 2 - and - 4 - for piston "E" - 3 -.
- Press piston "E" - 3 - into cylinder "E" - 1 - as far as stop.
- Insert dished washer - 5 -.
- Replace O-ring - 6 - on diaphragm plate - 7 -
- Insert diaphragm plate - 7 - into cylinder "E" - 1 -.

8 - Circlip





- Press diaphragm plate down under shop press using installation bracket T10276
- Insert new circlip - 1 -.

CAUTION:
Do not over-stretch circlip. After installing, check proper seating of circlip.

- Release shop press.





- Insert waved washer - 2 - into cylinder "E" - 1 -.
- Install outer plates - 3 - and coated plates - 4 - alternately.
- Install thick outer plates - 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 "E" air gap

- Secure pre-tensioning tool T10285 with wide base in vise.
- Install clutch "E" in pre-tensioning tool.

^ Input shaft projects through bore in base plate.

- Place plate T10291 on outer clutch disc "E".

^ Plate must not touch circlip all around.

- Insert pressure unit T10285/1 with centering pin into bore of plate.
- Align clutch "E" 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 the inspection hole of the pressure unit must align - arrow -.

- Insert dial gauge VAS 6080 into measuring bar VW 382/7 and tighten knurled nut.
- Apply measuring bar at upper edge of cylinder "E", as depicted in illustration.
- Check whether measuring bar makes proper contact at edge of cylinder "E".
- Position measuring tip on outer plate and note measuring value.
- Mark exact contact point on cylinder "E".
- 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 "E" and pull plate pack upward until stop.
- When disc pack is pulled up, measure distance between upper edge of cylinder "E" 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 "E" air gap - Automatic Transmission 01V Front Wheel Drive





Clutch "E" 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.