Input Shaft With 6 Lining Discs, Disassembling and Assembling
Input shaft with 6 lining discs, disassembling and assembling - 01J, Continuously Variable Transmission (CVT)
CAUTION!
^ Note the difference between input shafts with 6 and 7 lining discs
Special tools, testers and auxiliary items required
^ Pressure plate VW 401
^ Seal remover T40014
^ Assembly tool T10219/1
^ Tube 2010
^ Tube VW 416 B
Special tools, testers and auxiliary items required
^ Pressure stand T40099
^ 2 piece ruler T40100
^ 4 piece calipers T40101
^ 2 piece feeler gauge T40117 for input shafts with 6 lining discs
^ Digital depth gauge VAS 6087
^ Protective gloves
^ Ice spray
Work procedure
^ Transmission removed
Note:
^ Observe general repair notes.
^ Refer to Rules of cleanliness for working on automatic transmissions.
- Remove input shaft.
- Remove input shaft cover from shaft.
- Place input shaft on assembly tool T10219/1.
- Carefully raise thrust plate with pistons with two screwdrivers -arrows-.
Precautionary measures:
CAUTION!
^ The inner running and sealing surfaces -arrow A- of the thrust plate and pistons -arrow C- must not touch shaft during removal and installation.
^ The running and contact surfaces must not show the smallest signs of damage such as scratches or grooves as a result of removing or installing.
^ If damaged, the thrust plate or pistons must be replaced.
- Carefully guide thrust plate -1- with pistons -2- up over shaft -3-.
^ Inner running surfaces of thrust plate -1- and pistons -2- must not touch shaft.
Disc pack, removing
- Remove corrugated spring washer -5- , they must be used again.
- Remove upper adjustment disc -4- from input shaft cylinder -A-.
- Measure adjustment disc thickness -4- and note measurement.
- Remove all lining discs -2- and outer discs -3- from input shaft cylinder -A-.
- Remove lower adjustment disc -1- from input shaft cylinder -A-.
- Measure adjustment disc thickness -1- and note measurement.
CAUTION!
^ All old, used adjustment discs, outer discs and lining discs must be replaced. They must not be reinstalled as that would not ensure the input shaft function (surface is used up).
^ The corrugated spring washer must be used again.
Input shaft, assembling
CAUTION!
Before assembly, check for wear on transmission components.
- Replace ball bearing in input shaft cover.
- Adjust input shaft and determine air gap.
- Place input shaft on assembly tool T10219/1.
- Insert determined lower adjustment disc -1- in input shaft cylinder -A-.
- Insert alternately and with same alignment each lining disc -2- (6 pieces) and outer disc -3- (5 pieces, 1.9 mm thickness).
Lining disc alignment:
CAUTION!
^ The lining discs must be installed with the same alignment, that is the places without outside teeth -arrows- must always lie one on top of the other. Only in this way is the adjustment correct; you must mark the cylinder for correct installation, if necessary.
- Insert determined upper adjustment disc -4- in input shaft cylinder -A-.
- Lastly, insert corrugated spring washer -5-.
- Press pistons -1- into stop on thrust plate -2-.
CAUTION!
^ The inner running and sealing surfaces -arrow A- of the thrust plate and pistons -arrow C- must not touch shaft during removal and installation.
^ The running and contact surfaces must not show the smallest signs of damage such as scratches or grooves as a result of removing or installing.
^ If damaged, the thrust plate or pistons must be replaced.
- Carefully guide pressure plate -1- with pistons -2- down over shaft -3-.
^ Inner running surfaces of thrust plate -1- and pistons -2- must not touch shaft.
- Press thrust plate with pistons uniformly into input shaft up to stop.
Checking air play with feeler gauge T40117
- Insert both feeler gauges T40117 under thrust plate -A-.
- A second technician must push thrust plate -A- down to stop - arrow 1 - with Tube VW 416 B.
- Guide both feeler gauges T40117 circularly in direction of -arrow- back and forth under thrust plate.
^ Both feeler gauges T40117 must be guided oppositely.
^ Feeler gauges T40117 must not be angled.
^ Entire circular area must be checked.
^ Both feeler gauges T40117 must always move freely without slightest resistance.
If feeler gauges T40117 cannot be guided in direction of -arrow- without blocking:
- Repeat input shaft adjustment.
CAUTION!
Air play must pass check with feeler gauges T40117 , otherwise transmission will exhibit problems after reassembly.
If feeler gauges T40117 can be guided in direction of -arrow- without blocking:
- Install input shaft cover.
- Install input shaft.
- Install input shaft seal -A-.
- Fill with ATF.
CAUTION!
^ The Multitronic 01J or 0AN transmission requires a different ATF than shift automatics. Only ATF for CVT transmission which can be obtained as replacement part must be used in planetary gearing.
^ Flush ATF after installing transmission.