Audi Workshop Service and Repair Manuals

Dismantling and assembling clutch “D/G” with freewheel

Dismantling l  Clutch “D” faces upwards. –  Detach circlip -1- and remove set of plates -2- from cylinder “D/G”.

–  Turn cylinder “D/G” upside down. l  Clutch “G” faces upwards (dished spring is visible). –  Detach circlip -1- and remove set of plates -2- from cylinder “D/G”.

–  Place cylinder “D/G” on thrust piece -3301/4- under workshop press. –  Press dished spring down using workshop press with mounting bracket -T10289-. –  Detach circlip -1-, thrust washer and dished spring. –  Release workshop press.

WARNING Wear safety goggles. –  Carefully press piston “G” out of cylinder “D/G” by applying compressed air.

–  Press freewheel inner race -2- out of cylinder “D/G”-item 1--arrow- (if necessary, release by knocking lightly with a plastic hammer). –  Detach cylinder “D/G” from freewheel.

–  Turn cylinder “D/G” upside down. l  Cylinder “D” faces upwards.   WARNING Wear safety goggles. –  Carefully press piston “D” out of cylinder “D/G” by applying compressed air.

–  Dismantle freewheel. 6 -  Dished spring 5 -  Retaining plate 4 -  Freewheel with freewheel cage 3 -  Rectangular section seals 2 -  O-rings 1 -  Freewheel inner race

Assembling   Caution Before assembly, check the components of the freewheel, clutch “D” and clutch “G” for traces of wear and damage → Chapter. –  Renew O-rings -2- and -4- for piston “D”-item 3-. –  Push piston “D”, -item 3- into cylinder “D/G”, -item 1- as far as stop.

–  Fit corrugated spring -2- into cylinder “D/G”-item 1-. –  Fit outer plates -3- and friction plates -4- alternately. –  Insert thick outer plate -5-.   Note Make sure that the rounded edges of the thick outer plate face friction plate -4- and not circlip -6-. The contact surface for the circlip is thus increased. –  Insert circlip -6-.

Adjusting clearance of clutch “D” –  Fit clutch “D/G” onto compressor tool -T10285-. l  Clutch “D” faces upwards. –  Position holding plate -T10293- onto outer plate of clutch “D”. l  Avoid any contact between holding plate and circlip. –  Fit centring pin of thrust piece -T10285/1- into drilling in holding plate. –  Bring clutch “D/G” into correct position on holding plate of compressor tool. l  Thrust piece must be positioned centrally below thrust plate of spindle. –  Turn spindle of compressor tool downwards. l  The markings on the inspection hole of the thrust piece must align -arrow-. –  Apply digital depth gauge -VAS 6087- to upper rim of cylinder “D/G” as shown in illustration. –  Bring measuring tip into contact with outer plate and note value obtained. –  Mark measuring point on cylinder “D/G”. –  Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points. –  Determine average value from the three measurements under load. –  Release spindle and remove holding plate.

–  Use both hands to pull set of plates upwards in clutch “D” as far as stop. –  With set of plates pulled up as far as stop, measure distance between upper rim of cylinder “D/G” and outer plate at one of the points marked (assistance of second mechanic required). –  Repeat measurement at the two remaining markings on the outer plate. –  Determine average value from the three measurements with set of plates pulled up as far as stop. –  Determine clearance using the following formula:

	Mean value of measurements under load (value 1 + value 2 + value 3) : 3
–	Mean value of measurements with set of plates pulled up as far as stop (value 1 + value 2 + value 3) : 3
=	Clearance

–  Subtract mean value of measurement with set of plates pulled up as far as stop from mean value of measurements under load.

Clearance of clutch “D”, Automatic gearbox 01V, front-wheel drive

Gearbox code letters	Specification
EBV, EBW, EBX, EBZ, ECJ, EDC, EDE, EFP, EKC, EMA, ERY, ETK, ETL, ETZ, EYF, EZP, EZW, EZX, EZY, EZZ, FAD, FAE, FATF, FAH, FAJ, FAK, FED, FEE, FHV, FNL, FRT, GDE, GML	2.29 ... 2.59 mm
EBU, EBY, EZR, EZS, FAB, FEV	1.92 ... 2.22 mm
CJQ, CJU, CJW, CJX, CJY, CJZ, DCS, DDS, DDT, DEQ, DES, DEU, DPS, DRD, DRF, DUL, DUM, DSS, EFR, ETV, ETW, ETU, EZV, FAC	2.55 ... 2.85 mm
CJV	2.60 ... 2.92 mm

Clearance of clutch “D”, Automatic gearbox 01V, four-wheel drive

Gearbox code letters	Specification
CJP, CJR, CJS, CJT, DEV, DEW, DEX, DEY, DKB, DPT, DRK, DRN, DST, DTU, DTV, EKX, ETX, ETY, FAN, FHD	2.55 ... 2.85 mm
ECB, ECC, ECD, ECG, ECH, EDF, EKD, EMM, EMP, ETM, ETN, EUA, EYJ, EYK, EZB, FAM, FAP, FAQ, FAR, FAS, FAU, FAV, FAW, FAX, FAZ, FBA, FBB, FEF, FEG, FEJ, FEQ, FHF, FHG, FHH, FLC, FLV, FNM, FRU, FVE, FXL, GAK, GBG, GBH, GBJ	2.29 ... 2.59 mm
EFQ, FAL, FEP, GBF	1.92 ... 2.22 mm

If reading does not match specification: –  Determine new circlip -1- according to following table.   Note -Item 2- can be disregarded. l  If clearance is below specification: insert thinner circlip of appropriate thickness. l  If clearance is above specification: insert thicker circlip of appropriate thickness.

Available circlips - Thickness of circlips in mm
2.2	3.0	3.8
2.4	3.2	4.0
2.6	3.4	4.2
2.8	3.6

–  Check clearance again after inserting circlip.

–  After determining thickness of required circlip, detach circlip -1- and remove set of plates -2- from cylinder “D/G”.

–  Renew O-rings -2- and rectangular section seals -3- on freewheel inner race -1-. 4 -  Freewheel with freewheel cage 5 -  Retaining plate 6 -  Dished spring –  Lightly lubricate O-rings and rectangular section seals with vaseline before fitting. Use vaseline only. Other types of lubricant will cause the gearbox hydraulics to malfunction. –  Make sure that the rectangular section seals are seated properly all round in the grooves on the freewheel inner race.

–  Insert freewheel inner race -2- in freewheel -1- with freewheel cage as far as stop, turning clockwise as required -arrows-.

–  Place cylinder “D/G”, -item 1- onto 2 rectangular wooden blocks (approx. 40 mm high). l  Cylinder “D” faces upwards. –  Fit dished spring -2- and retaining plate -3- into cylinder “D/G”. l  Lugs on retaining plate face towards cylinder “D/G”. –  Take hold of freewheel -4- so that freewheel inner race cannot slip out, and push splines on freewheel inner race into splines of cylinder “D/G”.

–  Turn cylinder “D/G”-1- upside down (prevent freewheel inner race from slipping out). l  Cylinder “G” faces upwards. –  Place cylinder “D/G” on thrust piece -3301/4-. –  Renew O-rings -2- and -4- for piston “G”, -item 3-. –  Push piston “G”-item 3- into cylinder “D/G” as far as stop. –  Fit dished spring -5- and thrust washer -6-. l  The teeth on the thrust washer must engage in the splines of the freewheel inner race. 7 -  Circlip

–  Place cylinder “D/G” on thrust piece -3301/4- under workshop press. –  Press dished spring down using workshop press with mounting bracket -T10289-. –  Push down thrust washer as far as it will go and fit circlip -1-. –  Make sure that circlip locates securely all round in groove in freewheel inner race; press circlip into groove all round with a screwdriver if necessary. –  Release workshop press. –  Press dished spring down again to make sure freewheel is correctly installed. l  It should be possible to move thrust washer -item 6- ⇒ previous illustration “A37-10345”.

–  Fit corrugated spring -2- into cylinder “D/G”-item 1-. –  Fit outer plates -3- and friction plates -4- alternately. –  Insert thick outer plate -5-.   Note Make sure that the rounded edges of the thick outer plate face friction plate -4- and not circlip -6-. The contact surface for the circlip is thus increased. –  Insert circlip -6-.

Adjusting clearance of clutch “G” l  Clutch “G” faces upwards. –  Fit clutch “D/G” onto compressor tool -T10285-. –  Position holding plate -T10292- onto outer plate of clutch “G”. l  Avoid any contact between holding plate and circlip. –  Fit centring pin of thrust piece -T10285/1- into drilling in holding plate. –  Bring clutch “D/G” into correct position on holding plate of compressor tool. l  Thrust piece must be positioned centrally below thrust plate of spindle. –  Turn spindle of compressor tool downwards. l  The markings on the inspection hole of the thrust piece must align -arrow-. –  Apply digital depth gauge -VAS 6087- to upper rim of cylinder “D/G” as shown in illustration. –  Bring measuring tip into contact with outer plate and note value obtained. –  Mark measuring point on cylinder “D/G”. –  Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points. –  Determine average value from the three measurements under load. –  Release spindle and remove holding plate.

–  Use both hands to pull set of plates upwards as far as stop in clutch “G”. –  With set of plates pulled up as far as stop, measure distance between upper rim of cylinder “D/G” and outer plate at one of the points marked (assistance of second mechanic required). –  Repeat measurement at the two remaining markings on the outer plate. –  Determine average value from the three measurements with set of plates pulled up as far as stop. –  Determine clearance using the following formula:

	Mean value of measurements under load (value 1 + value 2 + value 3) : 3
–	Mean value of measurements with set of plates pulled up as far as stop (value 1 + value 2 + value 3) : 3
=	Clearance

–  Subtract mean value of measurement with set of plates pulled up as far as stop from mean value of measurements under load.

Clearance of clutch “G”, Automatic gearbox 01V, front-wheel drive

Gearbox code letters	Specification
CJV, CJW, CJX, CJY, CJZ, DCS, DEQ, DES, DEU, DPS, DRD, DSS, EFR, ETU, ETV, ETW, EZV, FAC	1.52 ... 1.82 mm
CJQ, CJU, DDS, DDT, DRF, DUL, DUM	1.15 ... 1.45 mm
EBW, EBX, EBZ, ECJ, EDC, EDE, EFP, EKC, EMA, ERY, ETK, ETL, ETZ, EYF, EZP, EZW, EZX, EZY, EZZ, FAB, FAE, FATF, FAH, FAJ, FAK, FED, FEE, FHV, FNL, FRT, GDE, GML	1.79 ... 2.08 mm
EBU, EBV, EBY, EZR, EZS, FAD, FEV	1.33 ... 1.62 mm

Clearance of clutch “G”, Automatic gearbox 01V, four-wheel drive

Gearbox code letters	Specification
CJP, CJR, CJS, CJT, DEV, DEW, DEX, DEY, DPT, DRK, DRN, DST, DTU, ECB, ECC, ECD, ECG, ECH, EDF, EKD, EKX, EMM, EMP, ETM, ETN, ETX, ETY, EUA, EYJ, EYK, EZB, FAM, FAN, FAP, FAQ, FAR, FAS, FAU, FAV, FAW, FAX, FAZ, FBA, FBB, FEF, FEG, FEJ, FHD, FHF, FHG, FHH, FLC, FLV	1.52 ... 1.82 mm
DKB, DTV	1.15 ... 1.45 mm
FEQ, FNM, FRU, FVE, FXL, GAK, GBG, GBH, GBJ	1.79 ... 2.08 mm
EFQ, FAL, FEP, GBF	1.33 ... 1.62 mm

If reading does not match specification: –  Determine new circlip -1- according to following table.   Note -Item 2- can be disregarded. l  If clearance is below specification: insert thinner circlip of appropriate thickness. l  If clearance is above specification: insert thicker circlip of appropriate thickness.

Available circlips - Thickness of circlips in mm
1.8	2.4	3.0
2.0	2.6	3.2
2.2	2.8	3.4

–  Turn clutch “D/G” upside down. l  Clutch “D” faces upwards. –  Install plates for clutch “D” together with correct new circlip as follows:

–  Fit corrugated spring -2- into cylinder “D/G”-item 1-. –  Fit outer plates -3- and friction plates -4- alternately. –  Insert thick outer plate -5-.   Note Make sure that the rounded edges of the thick outer plate face friction plate -4- and not circlip -6-. The contact surface for the circlip is thus increased. –  Insert circlip -6-.