Audi Workshop Service and Repair Manuals

Adjusting clutch play between “K1” and “K2” Special tools and workshop equipment required

t  Measuring tool -VW 382-

t  Dial gauge -VAS 6079-

t  Depth gauge -VAS 6082- Determining thickness of shim(s) -C- l  Planet carrier installed and adjusted → Chapter. l  For the measuring sequence the gearbox housing must be clamped into engine and gearbox support so that the input gear is facing downwards, as shown in illustration → Chapter.

The thickness of the shim is governed by gap dimension -x-. This gap dimension is calculated according to the following formula:    -x- = -a- – -b- 1 -  ATF pump 2 -  Reverse gear clutch “K2” 3 -  1st to 3rd gear clutch “K1” 4 -  3rd and 4th gear clutch “K3” C -  Shim(s) x -  Gap dimension a -  Installation position of clutch “K1”; determining value → Anchor b -  Size of ATF pump housing; determining value → Anchor →

Determining value “a” –  Place short straightedge -A- on pump flange in gearbox housing. –  Press “K1” downwards in direction of -arrow- and measure into “K1” using depth gauge -VAS 6082--item B-.

l  Example of value “a”:
Measured value	73.7 mm
– Straightedge	– 19.5 mm
= Determined value “a”	54.2 mm

Determining value “b” –  Fit paper gasket onto flange of ATF pump. –  Place straightedge -B- on stator support -arrow- and use depth gauge -VAS 6082--item A- to measure down to paper gasket on flange of ATF pump.

l  Example of value “b”:
Measured value	70.5 mm
– Straightedge	– 19.5 mm
= Determined value “b”	51.0 mm

l  Example for calculating gap “x”:    x = a – b l  x = 54.2 mm – 51.0 mm = 3.2 mm –  Determine shim(s) “C” according to following table: for part numbers refer to → Electronic parts catalogue:

Gap “x” (mm)	Shim(s) in mm
… 2.54	1.4
2.55 … 3.09	1.0 + 1.0
3.10 … 3.49	1.2 + 1.2
3.50 … 3.89	1.4 + 1.4
3.90 … 4.29	1.6 + 1.6
4.30 … 4.69	1.8 + 1.8
4.70 … 5.04	1.2 + 1.2 + 1.6
5.05 … 5.25	1.2 + 1.2 + 1.8

The shims are colour-coded according to thickness:

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

–  After installing ATF pump, carry out check measurement of clutch play as described in the following. Check measurement (clutch play) l  The clutch play cannot be measured until the ATF pump has been installed. l  Reverse gear clutch “K1” must be installed. –  Attach dial gauge holder to gearbox housing and place tip of dial gauge on turbine shaft with a preload of 1 mm.   Note

The gearbox must be moved to its installation position so that the turbine shaft can be moved.   Caution The turbine shaft may only be moved by hand as the use of tools would damage the splines. –  Pull turbine shaft out and push it in (shaft will be difficult to move) and read off play on dial gauge. Clutch play: l  Minimum: 0.5 mm. l  Maximum: 1.2 mm.