Input Shaft with 6 Lining Discs

Input Shaft with 6 Lining Discs


• Note the difference between input shafts with 6 and 7 lining discs. Refer to => [ Input Shaft, Servicing with 6 Lining Discs ] Input Shaft, Servicing with 6 Lining Discs

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Seal Ring Extractor (T40014)

• Assembly Tool (T10219/1)

• Pipe (2010)

• Tube 37 mm Dia. (VW 416 B)

• Pressure Stand (T40099)

• Ruler (1 Set = 2 Pieces) (T40100)

• Caliper (1 Set= 4 Pieces) (T40101)

• Feeler Gauge (T40117)

• Digital Depth Gauge (VAS 6087)

• Protective gloves

• Ice spray

Procedure

• Transmission removed.

• General repair instructions, refer to => [ Repair Information ] Repair Information.

• Automatic transmission clean working conditions, refer to => [ Clean Working Conditions ] Clean Working Conditions.

- Remove input shaft. Refer to => [ Input Shaft ] Input Shaft.

- Remove input shaft cover from shaft. Refer to => [ Input Shaft Cover ] Input Shaft Cover

- Place input shaft on (T10219/1).





- Carefully raise thrust plate with pistons with two screwdrivers - arrows -.

Precautionary measures:


• The inner running and sealing surfaces - arrow A - of the thrust plate and pistons - arrow C - must not touch shaft during removal and installation.

• The running and contact surfaces must not show the smallest signs of damage such as scratches or grooves as a result of removing or installing.

• If damaged, the thrust plate or pistons must be replaced.







- Carefully guide thrust plate - 1 - with pistons - 2 - up over shaft - 3 -.





• Inner running surfaces of thrust plate - 1 - and pistons - 2 - must not touch shaft.

Disc Pack, Removing

- Remove corrugated spring washer - 5 -, they must be used again.





- Remove upper adjustment disc - 4 - from input shaft cylinder - A -.

- Measure adjustment disc thickness - 4 - and note measurement.

- Remove all discs lining - 2 - and outer discs - 3 - from input shaft cylinder - A -.

- Remove lower adjustment disc - 1 - from input shaft cylinder - A -.

- Measure adjustment disc thickness - 1 - and note measurement.


• All old, used adjustment discs, outer discs and lining discs must be replaced. They must not be reinstalled as that would not ensure the input shaft function (surface is used up).

• The corrugated spring washer must be used again.

Input Shaft, Assembling


Before assembly, check for wear on transmission components. Refer to => [ Diagnosis and Testing ] 01J,0AN Continuously Variable Transmission.

- Replace the bearing A (input shaft ball bearing) in the shaft pump cover. Refer to => [ Bearing A in Input Shaft Cover ] Bearing A in Input Shaft Cover.

- Adjust input shaft and determine air gap. Refer to => [ Input Shaft with 6 Lining Discs, Adjusting with Air Gap Determination ] Input Shaft with 6 Lining Discs, Adjusting with Air Gap Determination.


• All old, used adjustment discs, outer discs and lining discs must be replaced. They must not be reinstalled as that would not ensure the input shaft function (surface is used up).

• The corrugated spring washer must be used again.

- Place input shaft on (T10219/1).





- Insert determined lower adjustment disc - 1 - in input shaft cylinder - A -.





- Insert alternately and with same alignment each lining disc - 2 - (6 pieces) and outer disc - 3 - (5 pieces, 1.9 mm thick).

Lining disc alignment:






• The lining discs must be installed with the same alignment, that is the places without outside teeth - arrows - must always lie one on top of the other. Only in this way is the adjustment correct; you must mark the cylinder for correct installation, if necessary.

- Insert determined upper adjustment disc - 4 - in input shaft cylinder - A -.





- Lastly, insert corrugated spring washer - 5 -.

- Press pistons - 1 - into stop on thrust plate - 2 -.






• The inner running and sealing surfaces - arrow A - of the thrust plate and pistons - arrow C - must not touch shaft during removal and installation.

• The running and contact surfaces must not show the smallest signs of damage such as scratches or grooves as a result of removing or installing.

• If damaged, the thrust plate or pistons must be replaced.

- Carefully guide thrust plate - 1 - with pistons - 2 - up over shaft - 3 -.





• Inner running surfaces of thrust plate - 1 - and pistons - 2 - must not touch shaft.

- Press thrust plate with pistons uniformly into input shaft up to stop.

Checking Air Play with (T40117)





- Insert both (T40117) under thrust plate - A -.

- A second technician must push thrust plate - A - down to stop - arrow 1 - with (VW 416 B).

- Guide both (T40117) circularly in direction of - arrow - back and forth under thrust plate.

• Both (T40117) must be guided oppositely.

• Feeler gauges (T40117) must not be angled.

• Entire circular area must be checked.

• Both (T40117) must always move freely without slightest resistance.

If (T40117) cannot be guided in direction of - arrow - without blocking:

- Repeat the input shaft adjustment. Refer to => [ Input Shaft with 6 Lining Discs, Adjusting with Air Gap Determination ] Input Shaft with 6 Lining Discs, Adjusting with Air Gap Determination.


Air play must pass check with (T40117), otherwise transmission will exhibit problems after reassembly.

If (T40117) can be guided in direction of - arrow - without blocking:

- Install input shaft cover. Refer to => [ Input Shaft Cover ] Input Shaft Cover.

- Install the input shaft. Refer to => [ Input Shaft ] Input Shaft





- Install the input shaft seal - A -. Refer to => [ Input Shaft Seal ] Input Shaft Seal.





- Fill the ATF. Refer to => [ ATF, Filling for ATF Flush ] ATF, Filling for ATF Flush.


• The Multitronic 01J transmission requires a different ATF than shift automatics. Only ATF for CVT transmission which can be obtained as replacement part must be used in planetary gear.

• Flush ATF after installing transmission => [ ATF Flush ] ATF Flush.