Audi Workshop Service and Repair Manuals

Dismantling and assembling input shaft

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Oil seal extractor -T40014-

t	Assembly tool -T10219/1-

t	Tube -2010-

t	Tube -VW 416 B-

t	Thrust piece -T40099-

t	2x ruler -T40100-

t	Gauge block -T40101-

t	Feeler gauges -T40102-

t	Digital depth gauge -VAS 6087-

t	Protective gloves

t

Ice spray

Dismantling input shaft l  Gearbox removed   Note t  → Chapter „Repair instructions“. t  → Chapter „Rules for cleanliness when working on the gearbox“. –  Remove input shaft → Chapter. –  Remove cover from input shaft → Chapter.

–  Set down input shaft on assembly tool -T10219/1-. –  Use two screwdrivers -arrows- to carefully lift pressure plate with piston.

To prevent damage:   Caution l  The inner contact and sealing surfaces -arrow A- of the pressure plate and the piston -arrow C- must not be allowed to make contact with the shaft on removal/installation. l  The contact and sealing surfaces must not exhibit the slightest signs of damage such as scratches or scoring caused by dismantling/assembly. l  In the event of damage, the pressure plate or piston must be renewed.

–  Carefully guide the pressure plate -1- with piston -2- upwards over the shaft -3-. l  When doing so, the inner contact surfaces of the pressure plate -1- and of the piston -2- must not make contact with the shaft.

Removing clutch pack –  Remove corrugated washer -5- (washer must be re-used). –  Take top shim -4- out of input shaft cylinder -A-. –  Measure thickness of shim -4- and note down value. –  Take all friction plates -2- and outer plates -3- out of input shaft cylinder -A-. –  Remove bottom shim -1- from input shaft cylinder -A-. –  Measure thickness of shim -1- and note down value.   Caution l  Always renew old used shims, outer plates and friction plates. They must not be re-installed otherwise proper operation of the input shaft cannot be assured (due to the worn surface). l  The corrugated washer must be re-used. Assembling input shaft   Caution Assess wear on gearbox components prior to assembly → Chapter. –  Renew ball bearing for input shaft → Chapter. –  Adjust input shaft and determine clearance → Chapter.   Caution l  Always renew old used shims, outer plates and friction plates. They must not be re-installed otherwise proper operation of the input shaft cannot be assured (due to the worn surface). l  The corrugated washer must be re-used.

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

–  Insert chosen bottom shim -1- in input shaft cylinder -A-. –  Now build up the clutch pack by alternately inserting one friction plate -2- followed by one outer plate -3-, 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.

–  Insert chosen top shim -4- in input shaft cylinder -A-. –  Finally insert corrugated washer -5-.

–  Press home piston -1- in pressure plate -2-.   Caution l  The inner contact and sealing surfaces -arrow A- of the pressure plate and the piston -arrow C- must not be allowed to make contact with the shaft on removal/installation. l  The contact and sealing surfaces must not exhibit the slightest signs of damage such as scratches or scoring caused by dismantling/assembly. l  In the event of damage, the pressure plate or piston must be renewed.

–  Carefully guide pressure plate -1- with piston -2- downwards over shaft -3-. l  When doing so, the inner contact surfaces of the pressure plate -1- and of the piston -2- must not make contact with the shaft. –  Evenly press home the pressure plate with piston in the input shaft.

Checking clearance with feeler gauges -T40102- –  Insert the two feeler gauges -T40102- underneath the pressure plate -A-. –  Have a second mechanic use the tube -VW 416 B- to press down the pressure plate -A- as far as it will go -arrow 1-. –  Move the two feeler gauges-T40102- back and forth in a circle beneath the pressure plate in direction of -arrow-. l  Apply the two feeler gauges -T40102- on opposite sides. l  Take care to keep the feeler gauges -T40102- straight. l  The entire circular area must be checked. l  The two feeler gauges -T40102- must always move freely without any resistance whatsoever. If the feeler gauges -T40102- cannot be moved in direction of -arrow- without becoming blocked: –  Repeat the input shaft adjustment procedure → Chapter.   Caution It is essential to obtain a successful result when checking the clearance with the feeler gauges -T40102-, as gearbox problems will otherwise be encountered when driving off from a standstill. If the feeler gauges -T40102- move freely in direction of -arrow-: –  Fit input shaft cover → Chapter. –  Install input shaft → Chapter. –  Fit input shaft oil seal → Chapter. –  Fill up with ATF after installing gearbox → Chapter „Filling up with ATF (for ATF purging procedure)“.