Audi Workshop Service and Repair Manuals

Dismantling and assembling clutch “F”

Dismantling –  Turn clutch -F- upside down. –  Detach circlip -1- and remove set of plates -2- from cylinder “F”.

–  Press dished spring down using workshop press with mounting bracket -T10289-. –  Remove split retaining ring -1-. –  Release workshop press. –  Detach thrust plate and dished spring.

–  Fit cylinder “F” onto clutch “D/G” with freewheel.   WARNING Wear safety goggles. –  Carefully press piston “F” out of cylinder “F” by applying compressed air as shown in illustration.

Assembling   Caution Before assembly, check the components of clutch “F” for traces of wear and damage → Chapter. –  Renew O-rings -2- and -4- for piston “F”, -item 3-. –  Push piston “F”, -item 3- into cylinder “F”, -item 1- as far as stop. –  Fit thrust plate -5-. –  Fit dished spring -6-. 7 -  Split retaining ring

–  Press dished spring down using workshop press with mounting bracket -T10289-. –  Insert split retaining ring -1-. l  Collar of split retaining ring faces downwards. –  Release workshop press.

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

Adjusting clearance of clutch “F” –  Place clutch “F” onto compressor tool -T10285-. –  Position holding plate -T10292- onto outer plate of clutch “F”. l  Avoid any contact between holding plate and circlip. –  Fit centring pin of thrust piece -T10285/1- into drilling in holding plate. –  Bring clutch “F” 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 “F” as shown in illustration. –  Bring measuring tip into contact with outer plate and note value obtained. –  Mark contact point on cylinder “F”. –  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 “F”. –  With set of plates pulled up as far as stop, measure distance between upper rim of cylinder “F” 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 “F”, Automatic gearbox 01V, front-wheel drive

Gearbox code letters	Specification
CJQ, CJU, DDS, DDT, DRF, DUL, DUM	1.50 ... 1.82 mm
CJV, CJW, CJX, CJY, CJZ, DEQ, DCS, DES, DEU, DPS, DRD, DSS, EFR, ETU, ETV, ETW, EZV, FAC	1.90 ... 2.20 mm
EBU, EBY, EZR, EZS, FAB, FEV	1.81 ... 2.10 mm
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	2.26 ... 2.55 mm

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

Gearbox code letters	Specification
DKB, DTV	1.50 ... 1.82 mm
CJP, CJR, CJS, CJT, DEV, DEW, DEX, DEY, DPT, DRK, DRN, DST, DTU, EKX, ETX, ETY, FAN, FHD	1.90 ... 2.20 mm
EFQ, FAL, FEP, GBH	1.81 ... 2.10 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, GBF, GBG, GBJ	2.26 ... 2.55 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
1.2	1.8	2.4
1.4	2.0	2.6
1.6	2.2	2.8

–  Check clearance again after inserting circlip.