Audi Workshop Service and Repair Manuals

Adjusting input shaft with 7 friction plates and determining clearance   Note t  Observe the general repair instructions → Chapter. t  Rules for cleanliness when working on the automatic gearbox → Chapter. l  Thoroughly clean all components prior to installation.

Measuring the clutch   Note t  This measurement determines the distance -K- on the clutch from the top shim to the contact ring at the shaft (contact surface of pressure plate). t  The corrugated washer -1- is fitted beneath the clutch pack for the measurement.

–  Set down input shaft on assembly tool -T10219/1-.

–  Insert new lower shim -1- of same thickness as old shim in cylinder of input shaft -A-. –  Then insert corrugated washer -2-.   Note The corrugated washer is only fitted at the bottom for measurement. On assembly it is fitted at the top again. –  Now build up the clutch pack by alternately inserting one friction plate -3- (total of 7) followed by one outer plate -4- (total of 6, thickness 1.9 mm), ensuring that they are aligned together.

Alignment of friction plates:   Note Illustration shows friction plates with old linings.   Caution The friction plates must be mutually aligned on installation, i.e. the areas with no external toothing -arrows- must always coincide. This is the only way to achieve correct setting. If necessary, mark the cylinder of the input shaft to ensure proper alignment on installation.   Note Old input shafts only have 6 friction plates and 5 outer plates. They must be replaced by the new clutch pack with 7 friction plates and 6 outer plates → Electronic parts catalogue.

–  As a final step, insert the new upper shim -5- of the same thickness as the old shim in the input shaft.   Note

To ensure accuracy, all tool and component surfaces must be absolutely clean when performing the following measurements. –  Place the four gauge blocks -T40101- on the upper shim.

–  Place a ruler -T40100- over the centre of each pair of gauge blocks -T40101-.

–  Use the digital depth gauge -VAS 6087- to take measurement to the shim and note down the measured value -A-. l  When taking measurements, the digital depth gauge -VAS 6087- must make flush contact with both rulers -T40100-.

–  Then use the digital depth gauge -VAS 6087- to take measurement to the contact ring at the shaft (contact surface of pressure plate) and note down the measured value -B-.

–  Subtract the two measured values “B – A” to obtain the distance -K- of the clutch. Calculation of distance -K- of clutch: “B – A = K”   Note The corrugated washer -1- is fitted beneath the clutch pack for the measurement. –  Repeat the measurement on the opposite side of the input shaft and again determine the distance -K- of the clutch. –  Move the four gauge blocks -T40101- and the two rulers -T40100- through 90° on the input shaft and repeat the measurements. –  Take the four values determined for the distance -K- of the clutch and calculate the mean value MK. Mean value: “(value 1 + value 2 + value 3 + value 4) : 4 = MK”

Measuring the pressure plate –  First check for damage and renew if necessary. –  Turn the pressure plate over and set it down on a flat, clean surface. –  Place the two gauge blocks -T40101- on the cleaned contact surface of the pressure plate. l  The gauge blocks -T40101- must make full contact with the clean contact surface and not rest on the edge.

–  Place the rulers -T40100- over the centre of the gauge blocks -T40101-. –  Use the digital depth gauge -VAS 6087- to take measurement to the upper contact surface and note down the measured value -A-.

–  Use the digital depth gauge -VAS 6087- to take measurement to the lower contact surface and note down the measured value -B-. –  Subtract the two measured values “B – A” to obtain the distance “D” of the two contact surfaces on the pressure plate. Calculation of distance “D” on pressure plate: “B – A = D” –  Repeat the measurement at 2 further points on the pressure plate, offset by 120° in each case. –  Calculate the mean value for the pressure plate MD from the three measured values. Mean value: “(value 1 + value 2 + value 3) : 3 = MD” Determining the clearance –  Determine clearance using the following formula:

	Mean value of pressure plate measurements “M D” (value 1 + value 2 + value 3) : 3
–	Mean value of clutch measurements “MK” (value 1 + value 2 + value 3 + value 4) : 4
=	Clearance

Clearance = “MD” – “MK” Clearance specification: 1.8 ± 0.2 mm. If result does not match specification: A - Measured value too low: –  Insert appropriately thinner shim. It may also be necessary to renew the bottom shim. –  Check clearance again after inserting new shim → Chapter. B - Measured value too high: –  Insert appropriately thicker shim. It may also be necessary to renew the bottom shim. –  Check clearance again after inserting new shim → Chapter. The following shims are available:

Available shims [thickness in mm]
1,90	2,15	2,65
2,90	3,15

Note The clearance can be adjusted by way of the upper and lower shims.

If result matches specification: –  Take all shims, friction plates, outer plates and the corrugated washer -5-, -4-, -3-, -2- and -1- out of input shaft cylinder -A-.   Caution This step is necessary as the corrugated washer -2- is fitted above the bottom shim -1- only when adjusting the input shaft. When assembling the input shaft, the corrugated washer is fitted at the top. –  Assemble the input shaft → Anchor.