Input Shaft With 7 Lining Discs
Input Shaft with 7 Lining Discs
CAUTION!
• Note the difference between input shafts with 6 and 7 lining discs => [ Input Shaft, Servicing with 7 Lining Discs ] Input Shaft, Servicing With 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)
• Pressure stand (T40099)
• 2 pieces Ruler (T40100)
• End dimension ( 1 set = 4 pieces) (T40101)
• Feeler gauge (1 set = 2 pieces) (T40102)
• Digital depth gauge (VAS 6087)
• Protective gloves
• Ice spray
Input shaft, disassembling
• Transmission removed
• Observe general repair notes => [ General Repair Information ] General Repair Information.
• Rules of cleanliness for working on automatic transmissions => [ Clean Working Conditions ] Clean Working Conditions.
- Remove input shaft => [ Input Shaft ] Input Shaft.
- Remove input shaft cover from shaft => [ Input Shaft Cover ] Input Shaft Cover
- 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 -.
• With old version of input shaft, only 6 lining discs and 5 outer discs are installed. They must also be replaced with new disc pack with 7 lining discs and 6 outer discs.
- 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 bearing "A" (transmission input shaft ball bearing) in the input shaft cover => [ Bearing A in Input Shaft Cover ] Bearing A in Input Shaft Cover.
- Adjust input shaft and determine air gap => [ Input Shaft with 7 Lining Discs, Adjusting with Air Gap Determination ] Input Shaft With 7 Lining Discs, Adjusting With Air Gap Determination.
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.
- 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 - (7 pieces) and outer disc - 3 - (6 pieces, 1.9 mm thickness).
Lining disc alignment:
• The illustration shows the lining discs with the old boot.
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; mark the input shaft cylinder for correct installation, if necessary.
• With old version of input shaft, only 6 lining discs and 5 outer discs are installed. They must also be replaced with new disc pack with 7 lining discs and 6 outer discs.
- 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 ( T40102)
- Insert both feeler gauges (T40102) 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 (T40102) circularly in direction of - arrow - back and forth under thrust plate.
• Both feeler gauges (T40102) must be guided oppositely.
• Feeler gauges (T40102) must not be angled.
• Entire circular area must be checked.
• Both feeler gauges (T40102) must always move freely without slightest resistance.
If feeler gauges (T40102) cannot be guided in direction of - arrow - without blocking:
- Repeat input shaft adjustment => [ Input Shaft with 7 Lining Discs, Adjusting with Air Gap Determination ] Input Shaft With 7 Lining Discs, Adjusting With Air Gap Determination.
CAUTION!
Air play must pass check with feeler gauges (T40102 ), otherwise transmission will exhibit problems after reassembly.
If feeler gauges (T40102) can be guided in direction of - arrow - without blocking:
- Install input shaft cover => [ Input Shaft Cover ] Input Shaft Cover.
- Install input shaft => [ Input Shaft ] Input Shaft.
- Install input shaft seal - A - => [ Input Shaft Seal ] Overhaul.
- Fill with ATF => [ ATF, Filling for ATF Flush ] ATF, Filling for ATF Flush.
CAUTION!
• The multitronic 01J 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 => [ ATF Flush ] ATF Flush.