Adjusting Input Shaft By Determining Air Play
Adjusting Input Shaft by Determining Air Play
Special tools, testers and auxiliary items required
• Assembly Tool (T10219/1)
• Calipers (T40101)
• Ruler (T40100)
• Digital Depth Gauge (VAS 6087)
• Refer to => [ Repair Information ] Repair Information.
• Refer to => [ Clean Working Conditions ] Clean Working Conditions.
Clutch Measurement
• The 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.
• All components must be cleaned thoroughly before inserting.
- Place input shaft on (T10219/1).
- Insert new lower adjustment disc - 1 - of the same thickness as the old in input shaft cylinder - A -.
- Insert corrugated spring washer - 2 -.
• 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 - and one externally toothed plate - 4 -.
Lining disc alignment:
• 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.
- Last, insert new upper shim - 5 - of same thickness as the old in the input shaft.
• For the following measurements, all tool and component surfaces must be completely clean in order to obtain exact values.
- Place 4 (T40101) on the upper shim.
- Lay a (T40100) centered over every 2 (T40101).
- Measure shim with (VAS 6087) and note measurement - A -.
• (VAS 6087) must lie flush on both (T40100) when measuring.
- Measure with (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 - of the clutch: "B - A = K"
• 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 (T40101) and 2 (T40100) at 90° on the input shaft and repeat measurements.
- Using 4 values determined for clutch distance - K -, calculate average MK.
Average: "(Value 1 + Value 2 + Value 3 + Value 4) : 4 = MK "
Thrust Plate Measurement
- First check for damage and replace, if necessary.
- Rotate thrust play and lay on level and clean surface.
- Place 2 (T40101) on cleaned thrust plate running surface.
• (T40101) must lie completely on clean running surfaces and must not lie on edge
- Lay (T40100) centered on (T40101).
- Measure shim with (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" in order to get the distance "D" between the two areas of the 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 MD.
Average: "(Value 1 + Value 2 + Value 3) : 3 = MD "
Determining Air Play
- Use the following calculation to determine air gap:
Air gap= "MD " - "MK "
• Air gap specified value: 1.8 +/- 0.2 mm.
If Specified Value Is Not Reached:
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. Refer to => [ Adjusting Input Shaft by Determining Air Play ] Adjusting Input Shaft By Determining Air Play.
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. Refer to => [ Adjusting Input Shaft by Determining Air Play ] Adjusting Input Shaft By Determining Air Play.
Following adjustment discs are available:
• Air gap can be adjusted using upper and lower adjustment discs.
If Specified Value Is Reached
- Remove all adjustment discs, lining discs, outer discs and the corrugated spring washer - 5 -, - 4 -, - 3 -, - 2 - and - 1 - from input shaft cylinder - A -.
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 => [ Assembling ] Input Shaft.