Clutch "E", Disassembling and Assembling

Clutch "E", disassembling and assembling, 01V, 5 SPD. A/T





^ Place clutch "E" - 1 - in mounting device T10283.





^ Remove circlip - 1 - and remove plate pack - 2 - from cylinder "E".





^ Press diaphragm plate down under shop press using installation bracket T10276.
^ Remove circlip - 1 -.
^ Release shop press.





^ Remove diaphragm plate - 7 -.
^Remove dished washer - 5 -.





^ Twist cylinder "E".

CAUTION: Wear protective glasses.

^ Carefully press piston "E" out of cylinder "E" with compressed air.

CAUTION: Before assembling, check individual components of clutch "E" for wear and damage.





^ Replace O-rings - 2 - and - 4 - for piston "E" - 3 -.
^ Press piston "E" - 3 -into cylinder "E" - 1 - until stop.
^ Insert dished washer - 5 -.
^ Replace O-ring - 6 - on diaphragm plate - 7 -.
^ Insert diaphragm plate - 7 - into cylinder "E" - item 1 -.





^ Press diaphragm plate down under shop press using installation bracket T10276.
^ Insert new circlip - 1 -.

CAUTION: Do not over-stretch circlip. After installing, check proper seating of circlip.

^ Release shop press.





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





Adjust air gap clutch "E"
Secure pre-tensioning tool T10285 with wide base in vise.
^ Install cylinder "E" in pre4ensioning tool.
- Input shaft projects through bore in base plate.
^ Position plate T10291 on outer plate clutch "E".
- Plate must not touch circlip.
^ Insert pressure unit T10285/1 with centering pin into bore of plate.
^ Align cylinder "E" 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 -.
^ Insert dial gauge VAS 6080 into measuring bar VW 382/7 and tighten knurled nut.
^ Apply measuring bar at upper edge of cylinder "E", as depicted in illustration.
^ Check whether measuring bar makes proper contact at edge of cylinder "E".
^ Position measuring tip on outer plate and note measuring value.
^ Mark exact contact point on cylinder "E".
^ Repeat measurement at 2 other points of outer plate, 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 "E" and pull plate pack upward until stop.
^ When plate pack is pulled up, measure distance between upper edge of cylinder "A" and outer plates (2nd mechanic required) at one of the marked points.
^ Repeat measurement at 2 other marked points of outer plate.
^ Average over 3 measured values when plate pack is pulled up.
^ Determine air gap on the 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 "E" Automatic Transmission 01V Front Wheel Drive





Air gap clutch "E" 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:





Check air gap of circlip again after inserting.