Input Shaft With 6 Lining Discs, Adjusting With Air Gap Determination

Input shaft with 6 lining discs, adjusting with air gap determination - 01J, Continuously Variable Transmission (CVT)

Note:
^ Observe general repair notes.
^ Rules of cleanliness for working on automatic transmissions.
^ All components must be cleaned thoroughly before inserting.

Clutch measurement





Note:
^ 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.





- 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 - (6 pieces) and outer disc - 4 - (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.





- 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 degrees 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 degrees.
- 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: 1.4 ± 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:





Note:
^ Air gap can be adjusted using upper and lower adjustment discs.

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.