Volkswagen Workshop Service and Repair Manuals

Adjusting clutch play between -K1- and -K2- This is the only adjustment work required for the installation of an exchange component.

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Support clamp -VW 313-

t	Gearbox support -VW 353-

t	Universal dial gauge bracket -VW 387-

t	Depth gauge

t	Straightedge

t	Dial gauge

–	To adjust clutch play, install components without shim → Item ⇒ Assembling planetary gearbox → Chapter.

1 -	Gearbox housing

q	→ Planetary gearbox installed up to small input shaft ⇒ Assembling planetary gearbox → Chapter.

2 -	Needle thrust bearing with washer

q	Needle thrust bearing faces small input shaft

q	Washer faces towards -K3-.

3 -	1st to 3rd gear clutch -K1- and 3rd and 4th gear clutch -K3- with turbine shaft

q	In some gearboxes, → clutches -K1- and -K3- may be pressed together as shown here.

q	There are two different types of turbine shaft, depending on the torque converter installed → Chapter.

4 -

Shims

q	Do not install when adjusting clutch play

q	Up to 3 shims can be installed

q	Shims are colour-coded according to thickness

5 -	Reverse gear clutch -K2-

q	Does not need to be installed for determining the shim(s)

q	Install for check measurement.

Calculating thickness of coloured shims –  Observe general repair instructions → Chapter. Prerequisites: l  Planet carrier is installed and adjusted ⇒ Assembling planetary gearbox → Chapter, Installing exchange component → Chapter l  Gearbox housing must be turned in assembly stand with input gear downwards for checking dimensions, as shown in → Item.

Shim to be measured -A- A -  Coloured shims 1 -  → ATF pump 2 -  Reverse gear clutch -K2- 3 -  1st through 3rd gear clutch -K1- 4 -  3rd and 4th gear clutch -K3- –  Calculate thickness of shim. Determine gap “x” and calculate shim thickness. Gap x = a - b Calculating a: l  Gearbox housing must be turned in assembly stand with input gear downwards for checking dimensions, as shown in → Item.

–  Place straightedge -A- on gearbox housing. –  Press -K1- downwards in direction of arrow and measure into -K1- using depth gauge -B-. Example: Measured value 1 = 88.5 mm

–  Measure with depth gauge -B- to pump flange on gearbox housing. Example: Measured value 2 = 34.3 mm

Measured value 1	=	88.5 mm
- Measured value 2	=	-34.3 mm
Calculated value a	=	54.2 mm

= Value measured from pump flange/gearbox housing into -K1-. Calculating b: –  Place new paper gasket on → ATF pump.

–  Place straightedge -B- on top of stator support -arrow- and measure with depth gauge -A- to gasket of pump flange. Example:

Measured value	=	70.5 mm
- Straightedge	=	-19.5 mm
Calculated value b	=	51.0 mm

Gap x = a - b = 54.2 mm - 51.0 mm = 3.2 mm –  Determine shims according to table → Anchor. –  Check clutch play dimension after installing → ATF pump → . Table of shims:

Gap-x- (mm)	Thickness of required shims (mm)	Colour of required shims
… 2.54 2.55 … 3.09 3.10 … 3.49	1.4 1 + 1 1.2 + 1.2	White Blue + blue Green + green
3.50 … 3.89 3.90 … 4.29 4.30 … 4.69	1.4 + 1.4 1.6 + 1.6 1.8 + 1.8	White + white Black + black Grey + grey
4.70 … 5.04 5.05 … 5.25	1.2 + 1.2 + 1.6 1.2 + 1.2 + 1.8	Green + green + black Green + green + grey

–  Determine thickness of shim from table. Shims have different thicknesses.

Blue	=	1.0 mm
Green	=	1.2 mm
White	=	1.4 mm
Black	=	1.6 mm
Grey	=	1.8 mm

In the previous example, it was calculated that x = 3.2 mm. Consequently, two green shims would be used in this example. If an exchange component is used: The exchange component contains shims of various colours and thicknesses to adjust the play between -K1- and -K2-. –  Select required shim; there are enough included in the exchange component. Measurement to check clutch play –  The clutch play cannot be measured until the → ATF pump has been installed. –  Attach dial gauge holder to gearbox housing and place dial gauge on turbine shaft with 1 mm preload.

–  Move turbine shaft up and down and read play on dial gauge. Play: min. = 0.5 mm max. = 1.2 mm