Audi Workshop Service and Repair Manuals

Dismantling and assembling clutch “E”

Dismantling –  Place clutch “E”-item 1- into support element -T10283-.

–  Detach circlip -1- and remove set of plates -2- from cylinder “E”.

–  Press retaining plate down using workshop press with mounting bracket -T10276-. –  Remove circlip -1-. –  Release workshop press.

–  Detach retaining plate -7-. –  Detach dished spring -5-.

–  Turn cylinder “E” upside down.   WARNING Wear safety goggles. –  Carefully press piston “E” out of cylinder “E” by applying compressed air.

Assembling   Caution Before assembly, check the components of clutch “E” for traces of wear and damage → Chapter. –  Renew O-rings -2- and -4- for piston “E”, -item 3-. –  Push piston “E”, -item 3- into cylinder “E”, -item 1- as far as stop. –  Fit dished spring -5-. –  Renew O-ring -6- on retaining plate -7-. –  Fit retaining plate -7- into cylinder “E”-item 1-. 8 -  Circlip

–  Press retaining plate down using workshop press with mounting bracket -T10276-. –  Fit new circlip -1-.   Caution Take care not to stretch circlip too far when installing. After installing, check that circlip is seated properly. –  Release workshop press.

–  Fit corrugated spring -2- in cylinder “E”-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 “E” –  Clamp support leg of compressor tool -T10285- in vice. –  Insert clutch “E” in compressor tool. l  The input shaft projects out of drilling in base plate. –  Position holding plate -T10291- onto outer plate of clutch “E”. l  Avoid any contact between holding plate and circlip. –  Fit centring pin of thrust piece -T10285/1- into drilling in holding plate. –  Bring clutch “E” 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-. –  Insert dial gauge -VAS 6080- into measuring bridge -VW 382/7- and secure with knurled nut. –  Position measuring bridge on upper rim of cylinder “E” as shown in illustration. –  Check that measuring bridge is seated properly on rim of cylinder “E”. –  Bring measuring tip into contact with outer plate and note value obtained. –  Mark exact contact point on cylinder “E”. –  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 “E” as far as stop. –  With set of plates pulled up as far as stop, measure distance between upper rim of cylinder “E” 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 “E”, Automatic gearbox 01V, front-wheel drive

Gearbox code letters	Specification
CJV, CJW, CJX, CJY, CJZ, DCS, DEQ, DES, DEU, DPS, DRD, DSS, EBV, EBW, EBX, EBZ, ECJ, EDC, EDE, EFP, EFR, EKC, EMA, ERY, ETK, ETL, ETU, ETV, ETW, ETZ, EYF, EZP, EZV, EZW, EZX, EZY, EZZ, FAC, FAD, FAE, FATF, FAH, FAJ, FAK, FED, FEE, FHV, FNL, FRT, GDE, GML	1.78 ... 2.08 mm
CJQ, CJU, DDS, DDT, DRF, DUL, DUM, EBU, EBY, EZR, EZS, FAB, FEV	1.41 ... 1.71 mm

Clearance of clutch “E”, 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, FEQ, FHD, FHF, FHG, FHH, FLC, FLV, FNM, FRU, FVE, FXL, GAK, GBG, GBH, GBJ	1.78 ... 2.08 mm
DKB, DTV, EFQ, FAL, FEP, GBF	1.41 ... 1.71 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

–  Check clearance again after inserting circlip.