SEAT Workshop Service and Repair Manuals

Dismantling and assembling input shaft with 7 friction plates Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter

Special tools and workshop equipment required

t	Pressure plate -VW 401-, see equivalent → Anchor

t	Seal extractor -T40014-

t	Assembly tool -T10219/1-

t	pressure tool -2010-

t	pressure tool -VW 416B-

t	pressure tool -T40099-

t	Ruler -T40100-

t	End measurement plate -T40101-

t	Feeler gauge -T40102-

t	Digital depth gauge -VAS 6087-

t	Wear protective gloves!

t

Ice spray

Dismantling input shaft. l  Gearbox removed   Note t  Observe the general repair instructions → Chapter. t  Cleaning norms when working on automatic gearbox. → Chapter –  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 upper 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 bearing „A“ (ball bearing for gearbox input shaft) in input shaft cover → 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 lower shim -1- in input shaft cylinder -A-. –  Then alternately insert one friction plate -2- (7x) and one outer plate -3- (6x, thickness 1.9 mm), ensuring mutual alignment.

Alignment of friction plates:   Note Illustration shows friction plates with old linings.   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 upper shim -4- in input shaft cylinder -A-. –  Finish by inserting 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 the feeler gauge -T40102- –  Place the feeler gauge -T40102- under the pressure disc -A-. –  A second mechanic must press the disc -A- downwards as far as it will go -arrow 1- using the press tool -VW 416B-. –  Move the feeler gauge -T40102- under the pressure disc in circles in the -direction of the arrow-. l  Move the feeler gauge -T40102- and hold on the opposite side as well. l  Do not tilt the feeler gauge -T40102-. 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 gauge -T40102- cannot be moved in the -direction of the arrow- without it being blocked: –  Repeat the input shaft adjustment procedure → Chapter.   Caution It is essential to obtain a successful result when checking the clearance with the feeler gauge -T40102-, as otherwise start-up problems will be encountered with the gearbox following re-installation. If the feeler gauge -T40102- can be moved in the -direction of the arrow- without it being blocked: –  Fit input shaft cover → Chapter.

–  Install input shaft → Chapter.

–  Mount the radial shaft seal for input shaft -A- → Chapter. –  Fill up with ATF → Chapter.   Caution t  The ATF required for the multitronic 01J gearbox is different to the ATF used for fixed-ratio automatic gearboxes. Only the ATF available as a replacement part for the CVT gearbox may be used in the planetary gearbox. ATF specification → Chapter. t  ATF must be refilled after fitting → Chapter.