Reverse Gear Clutch, Setting
Reverse Gear Clutch, Setting
Special tools, testers and auxiliary items required
• Digital Depth Gauge (VAS 6087)
• Digital Caliper, 150 mm (VAS 6335)
• 2 Ruler (T40100)
• Clean and flat measuring surface, for example, the pre-tensioning tool (T10285)
Setting the reverse gear clutch by determining the adjustment disc:
• General repair instructions, refer to => [ Repair Information ] Repair Information.
• Automatic transmission clean working conditions, refer to => [ Clean Working Conditions ] Clean Working Conditions.
Conditions:
• All components must be cleaned thoroughly before inserting.
• Transmission removed and secured to assembly stand => [ Securing Transmission in Vertical
Position ] Transmission, Securing in Engine/Transmission Holder.
• Reverse gear clutch with removed corrugated spring washer, refer to => [ Reverse Gear Clutch ] Reverse Gear Clutch.
• The following measurements serve for the determination of the upper adjustment discs - 5 - and lower - 2 - for the setting of the reverse gear clutch.
• For the following measurements, all tool and component surfaces must be completely clean in order to obtain exact values.
1. Measurement of the sealing surface of the input shaft on the surface of the corrugated spring washer, determination dimension - B -:
- Clean surfaces on the transmission housing, completely remove remaining seals.
- With the (VAS 6087), measure sealing surface of the input shaft on the surface of the corrugated spring washer in the transmission housing.
- Note measured value - B -.
- Repeat measurement on two different points and not the measured values.
- Determine and note the average value MB from the 3 measured values.
Average MB = Messwert B1 + B2 + B3/3
Example:
Average MB = 38.15 mm + 38.14 mm + 38.14 mm/3 = 38.143 mm
2. Measurement of the pre-tension clutch package, determination of dimension - A -:
• The corrugated spring washer - 2 - is installed under the disc pack to perform measurements.
• Use a clean and flat measuring surface as a flat surface - 1 -. In the following description, the (T10285) is used.
- First, place the corrugated spring washer - A - on the flat surface - 1 -.
- Then, alternating with the same direction for each lining disc - C - (6 pieces) and place an outer disc - B - ( 5 pieces) on the corrugated spring washer.
- Place all discs cleanly on top of each other.
- Place both (T40100) over the disc package.
• Through the weight of the (T40100), the air is pressed from the discs and the corrugated spring washer is subject to 2.5 kg (pre-tensed).
- Measure with the (VAS 6087) on the working space - 1 - and note the measurement - a -.
• Digital depth gauge (VAS 6087) must lie flush on both rulers (T40100) when measuring.
- Repeat measurement on the opposite side of the disc package and note the 2nd measured value.
- Move the 2 (T40100) by 90°.
- Repeat measurement and note the measured values 3 and 4.
- Determine and note the average value Ma from the 4 measured values.
Average Ma = Messwert a1 + a2 + a3 + a4/4
Determine dimension - A -
- Measure and note the thickness - b - of the (T40100).
Determine the height of the pre-tensed clutch package:
Measurement - A - = average Ma - - b -
- Note measurement - A - of the pre-tensed clutch package
Example:
Already determined: average MB = 38.143 mm
Thickness - b - of the (T40100) = 7.47 mm
Measurement - A - = average MB - - b - = 38.143 mm - 7.47 mm = 27.98 mm
3. Measurement of the sealing surface of the input shaft on the pistons of the reverse gear clutch, determination dimension - C -:
- Place a clean outer disc - 1 - on the removed input shaft.
• The outer disc - 1 - comes onto the piston of the reverse gear clutch through this. Through the flat outer disc, a correct measurement can be performed on the highest position of the piston. The thickness - d - of the outer disc - 1 - will be subtracted later to determine the amount of the piston.
- Measure with the (VAS 6087) on the sealing surface of the input shaft and note the measurement - D -.
- Repeat measurement on two different points and note the measured values.
- Determine and note the average value MD from the 3 measured values.
Average:
Average MD = Measure D1 + D2 + D3/3
- Remove the outer discs from the input shaft and measure and note the thickness - d -.
Measurement - C - of the sealing surface of the input shaft on the pistons of the reverse gear clutch:
- C - = average MD - thickness - d - of the outer discs - 1 -
- Note measurement - C -.
4. Determination of the thickness "E" of both adjusting discs:
- Determine the thickness of the adjusting discs according to the following calculation:
Determination>
E = MB + 0.27 mm - C - A - 3.0 mm
- With the calculated value E, select the thickness E1 of the adjusting disc according to table 1.
- Calculation of measurement M2 for the determination of the upper adjusting disc>
M2 = E - Thickness E1 of the selected lower adjusting disc
- With the measurement M2, select the thickness E2 of the adjusting clip according to table 2.
• Allocate adjustment shims.
- Measure and note the thickness of both selected adjusting discs.
• The actual thickness of the adjusting discs can be somewhat different due to the tolerances of the adjusting discs.
- Add the thicknesses of the two measured adjusting discs and note the value.
Thickness E1 measured + Thickness E2 measured = Thickness E Measured
Danger of driving problems after reinstalling the transmission.
The thicknesses of both selected adjusting discs must be smaller than the calculated measurement E.
Checking Calculation>
• Thickness E1 measured + Thickness E2 measured = Thickness E Measured
• Thickness E measured must be smaller than thickness E
- Install the reverse gear clutch with the selected adjusting discs. Refer to => [ Reverse Gear Clutch ] Reverse Gear Clutch
Example:
The following values are found in the example:
• Average MB = 38.143 mm
• "A" = 27.98 mm
• "C" = 2.98 mm
E = MB + 0.27 mm - C - A - 3.0 mm
E = 38.143 mm + 0.27 mm - 2.98 mm - 27.98 mm - 3.0 mm = 4.453 mm
- Determination of lower adjusting disc (thickness E1) from table 1:
Thickness E1 = 2.65 mm
- Calculation of measurement M2 for the determination of the upper adjusting disc>
M2 = E - Thickness E1 of the selected lower adjusting disc
M2 = 4.453 mm - 2.65 mm = 1.803 mm
- Determination of upper adjusting disc (thickness E2) from table 2:
Thickness E2 = not possible
• Since in this example the value 1.803 mm is outside of the selected measured area of table 2 (adjusting disc upper ), the next thinnest lower adjusting disc E1 must be selected from table 1 (lower adjusting disc ).
- Select thickness E1 from the next thinnest lower adjusting disc from table 1:
Thickness E1 = 2.15 mm
- Calculation of measurement M2 for the determination of the upper adjusting disc (thickness E2):
M2 = E - Thickness E1 of the selected lower adjusting disc
M2 = 4.453 mm - 2.15 mm = 2.303 mm
- Determination of upper adjusting disc (thickness E2) from table 2:
E2 = 2.15 mm
- Measure and note the thickness of both selected adjusting discs.
• The actual thickness of the adjusting discs can be somewhat different due to the tolerances of the adjusting discs.
- Add and note the thickness of both measured adjusting discs.
E1 measured + E2 measured = E Measured
Danger of driving problems after reinstalling the transmission.
The thicknesses of both selected adjusting discs must be smaller than the calculated measurement E.
Checking Calculation
• Thickness E1 measured + Thickness E2 measured = Thickness E Measured
• Thickness E measured must be smaller than thickness E
The following values are found in the example:
• E1 = 2.15 mm
• E2 = 2.15 mm
• E = 4.453 mm
(E1 + E2) < E
(2.15 mm + 2.15 mm) = 4.3 mm < 4.453 mm
The adjusting discs are not correctly selected for this example
- Reverse gear clutch can be installed.