Clutch "D/G" With Freewheel, Disassembling and Assembling

Clutch "D/G" with freewheel, disassembling and assembling, 01V, 5 SPD. A/T





^ Cylinder "D" faces upward.
^ Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".





^ Twist cylinder "D/G".
^ Cylinder "G" faces upward (dished washer is visible).
^ Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".





^ Place cylinder "D/G" on thrust piece 3301/4 under shop press.
^ Press dished washer down under shop press using installation bracket T10290.
^ Remove circlip - 1 - and remove thrust washer and dished washer.

CAUTION: Wear protective glasses.





^ Carefully press piston "G" out of cylinder "D/G" with compressed air.





^ Press freewheel inner race - 2 - out of cylinder "D/G" - 1 - - arrow -, loosen with light taps using a plastic hammer if necessary.
^ Remove cylinder "D/G" from freewheel.





^ Twist cylinder "D/G".
^ Cylinder "D" faces upward.

CAUTION: Wear protective glasses.

^ Carefully press piston "D" out of cylinder "D/G" with compressed air.





^ Disassemble freewheel:
6. Dished washer
5. Holding plate
4. Freewheel with freewheel housing
3. Rectangular rings
2. O-rings
1. Freewheel inner race

CAUTION: Before assembling, check individual components of freewheel, clutch "D" or clutch "G" for wear and damage.





^ Replace O-rings - 2 - and - 4 - for piston "D" - 3 -.
^ Press piston "D" - 3 - into cylinder "D/G" - 1 - until stop.





^ Insert wave washer - 2 - into cylinder "D/G" - 1 -.
^ Install outer plate - 3 - and coated plate - 4 - alternately.
^ Install thick outer plate - 5 -.
^ Insert circlip - 6 -.





Adjust air gap clutch "D"
^ Place cylinder "D/G" on pre-tensioning tool T10285.
^ Cylinder "D" faces upward.
^ Position plate T10293 on outer plate clutch "D".
^ Plate must not touch circlip all around.
^ Insert pressure unit T10285/1 with centering pin into bore of plate.
^ Align cylinder "D/G" on plate of pre4ensioning tool.
^ The pressure unit must be centrally positioned under spindle thrust piece.
^ Turn spindle of pre4ensioning tool downward.
^ The markings at inspection hole of pressure unit must align - arrow
^ Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G", as depicted in illustration.
^ Apply measuring tongue on outer plates and note measuring value.
^ Mark contact point on cylinder "D/G".
^ Repeat measurement at 2 other points of outer plates, 120° offset each, and mark contact points.
^ Average over 3 measured values under load.
^ Release spindle and remove plate.





^ Reach with both hands into clutch "D" and pull plate pack upward until stop.
^ When plate pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer plates (2nd mechanic required) at one of the marked points.
^ Repeat measurement at 2 other marked points of outer plates.
^ Average over 3 measured values when plate pack is pulled up.
^ Determine air gap on basis of the following calculations:





Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Air gap clutch "D" Automatic Transmission 01V Front Wheel Drive





Air gap clutch "D" Automatic Transmission 01V All Wheel Drive








If specified value is not obtained:
^ Determine new circlip - 1 -.

Note:
^ Disregard - 2 -.

^ Measured value too small: Install respectively thinner circlip.
^ Measured value too large: Install respectively thicker circlip.

The following circlips are available:





Check air gap of circlip again after inserting.





^ After having determined correct circlip, remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G" again.





^ Replace O-rings - 2 - and rectangular rings - 3 - on freewheel inner race - 1 -.
4. Freewheel with freewheel housing
5. Holding plate
6. Dished washer
^ Before inserting, thinly coat O-rings and rectangular rings with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
^ Make sure rectangular rings are fully seated all around in freewheel inner race grooves.





^ Insert freewheel inner race - 2 - until stop into freewheel - 1 - using turning motions in clockwise direction - arrows -.





^ Lay cylinder "D/G" - item 1 - on 2 wood blocks in height of approximately 40 mm.
^ Cylinder "D" faces upward.
^ Insert dished washer - 2 - and holding plate - 3 - into cylinder "D/G".
^ Tabs on holding plate face cylinder "D/G".
^ Grasp freewheel - 4 - so that the freewheel inner race can no longer slip out and press inner race splines into splines of cylinder "D/G".





^ Twist cylinder "D/G" - 1 -, secure freewheel inner race against slipping out while doing so.
^ Cylinder "G" faces upward.
^ Place cylinder "D/G" on thrust piece 3301/4.
^ Replace O-rings - 2 - and - 4 - for piston "G" - 3 -.
^ Press piston "G" - 3 - into cylinder "D/G" until stop.
^ Place dished washer - 5 - and thrust washer - 6 -.
^ Teeth of thrust washer must engage into splines of freewheel inner race.





^ Place cylinder "D/G" on thrust piece 3301/4 under shop press.
^ Press dished washer down under shop press using installation bracket T10290.
^ Push thrust washer fully downward and insert circlip - 1 -.
^ Make sure that circlip is seated evenly all around in groove of freewheel inner race, if necessary, press circlip into groove all around using screwdriver.
^ Release shop press.





^ Insert wave washer - 2 - into cylinder "D/G" - 1 -.
^ Install outer plates - 3 - and coated plates - 4 - alternately.
^ Install thick outer plates - 5 -.
^ Insert circlip - 6 -.





Adjust air gap clutch "G"
^ Cylinder "G" faces upward.
^ Place cylinder "D/G" on pre-tensioning tool T10285.
^ Position plate T10292 on outer plates clutch "G".
^ Plate must not touch circlip all around.
^ Insert pressure unit T10285/1 with centering pin into bore of plate.
^ Align cylinder "D/G" on plate of pre4ensioning tool.
^ The pressure unit must be centrally positioned under spindle thrust piece.
^ Turn spindle of pre4ensioning tool downward.
^ The markings at inspection hole of pressure unit must align - arrow
^ Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G", as depicted in illustration.
^ Apply measuring tongue on outer plates and note measuring value.
^ Mark contact point on cylinder "D/G".
^ Repeat measurement at 2 other points of outer plates, 120° offset each, and mark contact points.
^ Average over 3 measured values under load.
^ Release spindle and remove plate.





^ Reach with both hands into clutch "G" and pull plate pack upward until stop.
^ When plate pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer plates (2nd mechanic required) at one of the marked points.
^ Repeat measurement at 2 other marked points of outer plates.
^ Average over 3 measured values when plate pack is pulled up.
^ Determine air gap on basis of the following calculations:





Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Air gap clutch "G" Automatic Transmission 01V Front Wheel Drive





Air gap clutch "G" Automatic Transmission 01V All Wheel Drive








If specified value is not obtained:
^ Determine new circlip - 1 -.

Note:
^ Disregard - item 2
^ Measured value too small: Install respectively thinner circlip.
^ Measured value too large: Install respectively thicker circlip.

The following circlips are available:





Twist cylinder "D/G".
Cylinder "D" faces upward.
^ Install plates for clutch "D" with newly determined circlip as follows:





^ Insert wave washer - 2 - into cylinder "D/G" - 1 -.
^ Install outer plates - 3 - and coated plates - 4 - alternately.
^ Install thick outer plates - 5 -.
^ Insert circlip - 6 -.