Clutch Play Between -K1- and -K2-, Adjusting

Clutch play between -K1- and -K2-, adjusting, 01M, 4 Spd. A/T

Special tools and equipment required:

^ VW 309 Holding plate
^ VW 313 Support clamp
^ VW 353 Transmission support
^ VW 387 Universal dial indicator bracket
^ Depth gauge
^ Straightedge
^ Dial indicator

Note: To adjust clutch play install components without shim (item 4) go to Assembling planetary gearbox.





1 - Transmission housing
^ Planetary gearbox installed up to small input shaft go to assembling planetary gearbox

2 - Axial needle bearing with washer
^ Axial needle bearing faces small input shaft
^ Washer faces -K3-

3 - 1st to 3rd gear clutch -K1 - with 3rd and 4th gear clutch -K3-
^ 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 installed and adjusted go to Assembling planetary gearbox
^ For the measuring sequence the transmission housing must be clamped into the assembly stand so that the input gear is facing downward.





Determining shim -A-
A - Shim
1 - ATF pump
2 - Reverse gear clutch -K2-
3 - 1st to 3rd gear clutch -K1-
4 - 4th gear clutch -K3-
- Determine gap x and calculate shim thickness.
Gap x = a - b

Calculating "a":
^ For the measuring sequence the transmission housing must be clamped into assembly stand so that the input gear is facing downward.





- Place straightedge A onto transmission housing.
- Press -K1- together with -K3- down in direction of arrow and measure distance into -K1- with depth gauge B.

Example:
Reading 1 = 88.5 mm





- Measure with depth gauge B to pump flange on transmission housing.

Example:
Reading 2 = 34.3 mm





= Size measured from pump flange/transmission housing into -K1-

Calculating "b":
- Place new paper gasket onto ATF pump.





- Place straightedge -B- onto stator support (arrow) and measure with depth gauge -A- to gasket of pump flange.

Example:





Gap x = a - b
= 54.2 mm - 51.0 mm = 3.2 mm

- Determine size of shim according to table:

Table of shims





- Determine thickness of shims according to table and determine Part No. from parts catalog.
- Perform clutch play check measurement after installing ATF pump.

Check measurement (clutch play)
The clutch play cannot be measured until the ATF pump has been installed.
- Attach dial indicator holder to transmission housing and place indicator on turbine shaft with a preload of 1 mm.





- Move turbine shaft up and down and read of play on dial indicator gauge.

^ Play:
^ minimum = 0.5 mm
^ maximum = 1.2 mm