Clutch "A", Disassembling and Assembling

Clutch "A", disassembling and assembling - 5 Spd. A/T 01V Front and All Wheel Drive

Disassembling

- Rotate clutch "A".





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





- Press plate spring down under shop press using installation bracket T10276
- Remove split retaining ring - 1 -.
- Release shop press.
- Remove dished washer.





- Press ring - 2 - with O-ring - 3 - out of cylinder "A" - 1 -.

CAUTION:
Wear eye protection.





- Carefully press piston "A" out of cylinder "A" with compressed air, to do so plug two other oil bores using fingers.

Assembling

CAUTION:
Before assembling, check clutch components "A" for wear and damage.





- Replace O-rings - 2 - (green), - 3 - (black) and - 5 - (black) for piston "A" - 4 -.
- Press piston "A" - 4 - into cylinder "A" - 1 - as far as stop.
- Position plate spring - 6 -.

7 - Split retaining ring





- Press plate spring down under shop press using installation bracket T10276.
- Install split retaining ring - 1 -.

^ Bent inner side at right angle of retaining ring faces downward.

- Release shop press.





- Insert waved washer - 2 - into cylinder "A" - 1 -.
- Install outer plate - 3 - and coated plate - 4 - alternately.
- Install thick outer plate - 5 -.

Note:
^ Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

- Insert circlip - 6 -.





Adjust clutch "A" air gap

- Place clutch "A" on pre-tensioning tool T10285
- Place plate T10293 on outer clutch disc "A"

^ Plate must not touch circlip all around.

- Insert pressure unit T10285/1 with centering pin into bore of plate.
- Align clutch "A" on plate of pre-tensioning tool.

^ The pressure unit must be centrally positioned under spindle thrust piece.

- Turn spindle of pre-tensioning tool downward.

^ The markings at the inspection hole of the pressure unit must align - arrow -.

- Apply Digital depth gauge VAS 6087 at upper edge of cylinder "A" as depicted in illustration.
- Apply measuring tongue on outer plate and note measuring value.
- Mark contact point on cylinder "A".
- 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 "A" and pull plate pack upward until stop.
- When disc pack is pulled up, measure distance between upper edge of cylinder "A" and outer disc (2nd technician required) at one of the marked points.
- Repeat measurement at 2 other marked points of outer plate.
- Average over 3 measured values when pate 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.

Clutch "A" air gap - Automatic Transmission 01V Front Wheel Drive





Clutch "A" air gap - Automatic Transmission 01V All Wheel Drive





If specified value is not obtained:





- Determine new circlip - 1 - according to the following table.

Note:
^ Disregard - 2 -

^ Air gap too small: Install respectively thinner circlip.
^ Air gap too large: Install respectively thicker circlip.





- Check air gap of circlip again after inserting.





- Replace O-ring - 3 - on ring - 2 -.
- Press ring into cylinder "A" - 1 - until stop.