Input Shaft With 7 Lining Discs, Adjusting With Air Gap Determination
Input shaft with 7 lining discs, adjusting with air gap determination - 01J, Continuously Variable Transmission (CVT)
Note:
^ Observe general repair notes.
^ Refer to Rules of cleanliness for working on automatic transmissions.
^ All components must be cleaned thoroughly before inserting.
Clutch measurement
Note:
^ Distance - K - of the clutch from the upper contact ring shim on the shaft (Thrust plate contact surface) is determined.
^ The corrugated spring washer -1- is installed under the disc pack to perform measurements.
- Place input shaft on assembly tool T10219/1.
- Insert new lower adjustment disc -1- of same thickness as old in input shaft cylinder -A-.
- Insert corrugated spring washer -2-.
Note:
^ The corrugated spring washer is installed at the bottom only for measurement, it is installed again at the time during assembly.
- Insert alternately and with same alignment each lining disc -3- (7 pieces) and outer disc -4- (6 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.
Note:
^ With old version of input shaft, only 6 lining discs and 5 outer discs are installed. They must be replaced with new disc pack with 7 lining discs and 6 outer discs.
- Last, insert new upper shim -5- of same thickness as old in input shaft.
Note:
^ For the following measurements, all tool and component surfaces must be completely clean in order to obtain exact values.
- Place 4 calipers T40101 on upper shim.
- Lay a ruler T40100 centered over every 2 calipers T40101.
- Measure shim with digital depth gauge VAS 6087 and note measurement -A-.
^ Digital depth gauge VAS 6087 must lie flush on both rulers T40100 when measuring.
- Measure with digital depth gauge VAS 6087 on shaft contact ring (Thrust plate contact surface) and note measurement -B-.
- Subtract both measurements "B A" , to obtain clutch distance - K -.
Clutch distance calculation - K -: "B A = K"
Note:
^ The corrugated spring washer -1- is installed under the disc pack to perform measurements.
- Repeat measurement on opposite side of input shaft and also determine clutch distance - K -.
- Insert 4 calipers T40101 and 2 rulers T40100 at 90° on input shaft and repeat measurements.
- Using 4 values determined for clutch distance - K - , calculate average M K.
Average: " (Value 1 + Value 2 + Value 3 + Value 4): 4 = M K "
Thrust plate measurement
- First check for damage and replace, if necessary.
- Rotate thrust play and lay on level and clean surface.
- Place 2 calipers T40101 on cleaned thrust plate running surface.
^ Calipers T40101 must lie completely on clean running surfaces and must not lie on edge
- Lay rulers T40100 centered on calipers T40101.
- Measure shim with digital depth gauge VAS 6087 on upper running surface and note measurement -A-.
- Measure with digital depth gauge VAS 6087 on lower running surface and note measurement -B-.
- Subtract value of both measurements "B A" to determine distance "D" of both running surfaces to thrust plate.
Thrust plate distance calculation "D": "B A = D"
- Repeat measurement on 2 additional places on thrust plate off-set at 120°.
- Using these three measurements, calculate thrust plate average M D.
Average: " (Value 1 + Value 2 + Value 3): 3 = M D "
Determining air play
- Determine air gap on the basis of the following calculations:
Air gap specified value: 1.8 ± 0.2 mm.
If specified value is not obtained:
A-Measured value too small:
- Insert corresponding thinner adjustment disc, lower adjustment disc must also be replaced, if necessary.
- Check air gap again after installing new adjustment disc.
B-Measured value too large:
- Insert corresponding thicker adjustment disc, lower adjustment disc must also be replaced, if necessary.
- Check air gap again after installing new adjustment disc.
Following adjustment discs are available:
Available Adjustment Discs [Thickness In mm]:
If specified value is obtained:
- Remove all adjustment discs, lining discs, outer discs and the corrugated spring washer -5- , -4- , -3- , -2- and -1- from input shaft cylinder -A-.
CAUTION!
This step is necessary because the corrugated spring washer -2- is only installed over the lower adjustment disc -1- in order to adjust the input shaft. When assembling the input shaft, the corrugated spring washer is installed in the upper position.
- Assemble input shaft.