Clutch "D/G" With Freewheel

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





1. Freewheel inner race
^ Checking rotating and locking direction of freewheel
^ Checking brass sleeves for wear
^ Checking splines

3. Rectangular rings
^ Checking for wear

4. Freewheel with freewheel housing
^ Checking rotating and locking direction of freewheel

7. Coated plates
^ Checking for wear

8. Outer plates
^ Checking for wear

11. Dished washer
^ Replace in case of signs of wear or if dished washer tips are bent

15. Cylinder "D/G"
^ Checking for signs of wear caused by coated plates
^ Checking splines
^ Checking for cracks in area of groove for circlip

19. Dished washer
^ Replace in case of signs of wear or if dished washer tips are bent

23. Coated plates
^ Checking for wear

24. Outer plates
^ Checking for wear





Checking rotating and locking direction of freewheel
^ Freewheel inner race - 2 - must be able to turn in a clockwise direction and must lock in a counter-clockwise direction when turned.

If there is no locking effect:
^ Replace freewheel with freewheel housing - 1 -.





Checking upper and lower brass sleeves in freewheel inner race for wear
^ Check contact surfaces of brass sleeves - arrows - at inside of freewheel inner race for wear.
^ Contact surfaces must not be heavily scored and/or show blue discoloration.
^ Replace freewheel inner race if necessary.

If no blue discoloration and only small grooves are detected, proceed as follows:
^ Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
^ Carefully wipe off with a clean rag and check contact surfaces.
^ Contact surfaces must now be like new.

If scores cannot be removed in this manner:
^ Replace freewheel inner race.





Checking rectangular rings for wear

Note:
^ Always replace rectangular rings. However, conclusions can be drawn from the signs of wear of the rectangular rings regarding the quality of contact surface for rectangular rings. Evaluating the rectangular rings for wear is therefore essential.

If rectangular rings show strong axial wear of more than 0.3 mm - arrow 1 - (slight wear of outer edges is normal):
^ Replace freewheel inner race.

If rectangular rings show strong radial wear of more than 0.3 mm - arrow 2 - (for comparison, measure thickness of new rectangular ring):
^ Replace cylinder "F".





Checking coated and outer plates for wear

Signs of overheating on outer plates point to worn coated plates. Evaluate signs of wear as follows:

A - Spot of discoloration of outer plates caused by overheating in distance of more than 20 mm: Outer and coated plates OK can be reused.
B - Spot of discoloration of outer plates caused by overheating in distance of less than 20 mm: Outer and coated plates worn, must be replaced.
C - Tarnish blue/brown at outer and/or inner area of outer plates: Outer and coated plates overheated and worn, must be replaced.





Signs of wear at cylinder "D/G" caused by coated plates
^ Check cylinder at inner and outer circumference for signs of wear caused by coated plates.
^ Coated plates must not get caught in gashes.
^ If gashes - arrows - caused by coated plates are greater than 0.5 mm:
^ Replace cylinder "D/G".