Audi Workshop Service and Repair Manuals

Adjusting input shaft and checking clearance   Note t  → Chapter „Repair instructions“. t  → Chapter „Rules for cleanliness when working on the gearbox“.

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

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

–  Insert new bottom 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- followed by one outer plate -4-, ensuring that they are aligned together.

Alignment of friction plates:   Caution The friction plates must be aligned together when installed, i.e. the areas with no external teeth -arrows- must be stacked on top of each other. This is the only way to ensure correct adjustment. If necessary, mark the input shaft cylinder to ensure proper alignment on installation.

–  Finally insert new upper shim -5- of same thickness as old shim in input shaft.   Note

To ensure accuracy, the surfaces of all tools and components must be absolutely clean when performing the following measurements. –  Place the four gauge blocks -T40101- on the top shim.

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

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

–  Then use digital depth gauge -VAS 6087- to measure down to contact ring on shaft (contact surface of pressure plate) and note down 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 digital depth gauge -VAS 6087- to measure down to upper contact surface and note down measured value -A-.

–  Use digital depth gauge -VAS 6087- to measure down to lower contact surface and note down 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“ l  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 means of the top and bottom 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.