audi Workshop Repair Guides

Audi Workshop Service and Repair Manuals

Removing and installing multiple clutch > < Rules for cleanliness when working on the gearbox
Exploded view - multiple clutch
Exploded view - multiple clutch
t  The clutch in the direct shift gearbox 02E consists of two sets of plates, or clutch packs, and is therefore referred to as a “multiple clutch”. The larger clutch pack (located on the outside) is designated “K 1” (clutch 1), and controls the torque flow for reverse gear and gears “1”, “3” and “5”. The smaller set of plates (on the inside) is designated “K 2” (clutch 2), and controls the torque flow for gears “2”, “4” and “6”.
t  Any work performed on the multiple clutch requires extra care: all the parts are balanced and matched together in production. If the components are rotated out of their original positions when repairing, this will cause imbalance and impair the smoothness of the gearchanges and reduce the service life of the unit.
   
Replacement parts
1 - Multiple clutch with circlip
  Caution
t  The drive plate (top section of multiple clutch) of a new clutch is not secured with the circlip, it is only a “close fit” in the clutch.
t  The drive plate must remain engaged between the splines of the outer plate carrier.
t  If the drive plate comes loose, the clutch plates can slip out of position inside the multiple clutch unit. If this happens, it may not be possible to adjust the multiple clutch correctly during installation.
2 - Circlip
q   10x, with different thicknesses for adjusting
q   The thickness of the required circlip must be determined when installing the clutch → Anchor
3 - Clutch end cover
4 - Circlip for clutch end cover

   
Component parts of dismantled multiple clutch
  Caution
t  This illustration serves only as an overview of components; at the present time the multiple clutch must NOT be dismantled, as all outer and inner plates are matched and balanced before installation.
t  If the drive plate is loosened, the plates can slip out of position inside the multiple clutch unit. If this happens, it may not be possible to adjust the multiple clutch correctly during installation.
1 - Multiple clutch/clutch housing
q   Outer plate carrier
2 - Oil seals
q   4x
3 - Inner plate carrier
q   Do not remove
  Caution
DO NOT remove or lift up the inner plate carrier. This could cause the plates to move out of their original positions.
4 - Outer plates
q   4x
5 - Inner plates
q   4x
6 - Thrust washer
7 - Circlip
q   Fit a new circlip of the same thickness if the original circlip is removed in order to re-install the clutch plates.
8 - Circlip
q   Re-determine thickness when installing a new clutch → Anchor
9 - Drive plate
10 - Circlip
q   Renew

   

Removing and installing multiple clutch > < Rules for cleanliness when working on the gearbox