Clutch Play Between K1 and K2

Clutch play between -K1- and -K2-, adjusting

Required special tools and equipment:
^ VW 309 fixture
^ VW 313 Support clamp
^ VW 353 Transmission support
^ VW 387 Universal dial gauge bracket
^ Depth gauge
^ Straight edge
^ Dial gauge





- To adjust clutch play, install components without shim (item 4).

1 Transmission housing
^ Planetary transmission installed up to small input shaft.
2 Axial needle bearing with washer
^ Axial needle bearing faces toward small input shaft.
^ Washer faces toward -K3-
3 1st to 3rd gear clutch -K1- with 3rd and 4th gear clutch -K3-
^ The clutches -K1- and -K3- are pressed together
4 Shim
^ Do not install when adjusting clutch play
^ 1 or 2 shims can be installed
5 Reverse gear clutch -K2-

Conditions:
^ Planet carrier must be installed and adjusted refer to Planetary transmission, assembling
^ For performing the measurements, the transmission housing must be clamped into assembly stand with the input gear facing downward.

Shim -A-, determining





A Shim
1 ATF pump
2 Reverse gear clutch -K2-
3 1st to 3rd gear clutch -K1-
4 4th gear clutch -K3-
^ To calculate thickness of shim, determine gap "Y" .
Gap x = a - b

Calculating "a":
^ For the measurement, the transmission housing must be clamped into assembly stand with the input gear facing downward.





^ Place straight edge -A- on transmission housing.
^ Press -K1- together with -K3- down indirection of arrow and measure distance inside -K1- with depth gauge -B-.
Example:
Reading 1 = 88.5 mm
-Reading 2 = -34.3 mm
Calculated size a = 54.2 mm





^ Measure with depth gauge -B- to pump flange on transmission housing.
^ measured distance from pump flange/transmission housing into -K1-.

Calculating "b":
^ Place new paper gasket on ATF pump.








^ Place straight edge -B- on stator support -arrow- and measure with depth gauge -A- to gasket of pump flange.
Example:
Reading = 70.5 mm
Straight Edge = -19.5 mm
Calculated Size b = 51.0 mm
Gap X = a - b
= 54.2 mm - 51.0 mm = 51.0
Determine size of shim according to table:





Table of shims:
^ Be sure thickness of shims is according to the table. Determine Part No. from parts catalog.
^ Check clutch play measurement after installing ATF pump.

Clutch play measurement, checking
^ The clutch play cannot be measured until the ATF pump has been installed.
^ Attach dial gauge holder to transmission housing and place dial gauge on turbine shaft with a preload of 1 mm. Move turbine shaft up and down and read play on dial gauge.
Play:
min. = 0.5 mm
max. = 1.2 mm





^ Move turbine shaft up and down and read play on dial gauge.
Play:
min. = 0.5 mm
max. = 1.2 mm