Clutch "C" , disassembling and assembling

WARNING: This page is about a different car, the 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

General repair notes → General Repair Notes .
Rules of cleanliness for working on automatic transmissions → Rules of cleanliness for working on automatic transmissions .
Lubricate O-rings and gaskets with ATF or Vaseline before installing to prevent rings from being pinched when inserting.
Attach mount and adjustment shims only with Vaseline.

Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause faults to occur in the transmission hydraulics.

Disassembling

Twist ATF pump.

Fig 1: Identifying Circlip and Plate Pack

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove circlip - 1 - and remove plate pack - 2 - from cylinder "C".

Fig 2: Pressing Plate Spring Down Under Shop Press Using Installation Bracket T10289

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press plate spring down under shop press using installation bracket T10289.
Remove split retaining ring - 1 -.
Release shop press.

Fig 3: Identifying Dished Washer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove dished washer - 5 -.

CAUTION: Wear eye protection.

Fig 4: Carefully Press Piston "C" Out Of ATF Pump With Compressed Air

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully press piston "C" out of ATF pump with compressed air.

Assembling

CAUTION: Before assembling, check components of clutch "C" for wear and damage → Clutch "C" .

Fig 5: Identifying Dished Washer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace O-rings - 2 - and - 4 - for piston "C" - 3 -.
Press piston "C" - 3 - into ATF pump - 1 - until stop.
Position plate spring - 5 -.

6 - Split retaining ring

Fig 6: Pressing Plate Spring Down Under Shop Press Using Installation Bracket T10289

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press plate spring down under shop press using installation bracket T10289.
Install split retaining ring - 1 -.

Bent inner side at right angle of retaining ring faces downward.

Release shop press.

Fig 7: Cylinder Component, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert waved washer - 2 - into cylinder "B" - 1 -.
Install outer plates - 3 - and coated plates - 4 - alternately.
Install thick outer plate - 5 -.

NOTE:

Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

Insert circlip - 6 -.

Adjust clutch "C" air gap

Fig 8: Adjust Clutch "C" Air Gap Using Pre-Tensioning Tool T10285

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure pre-tensioning tool T10285 with wide base in vise.
Place ATF pump on pre-tensioning tool.

Stator shaft projects through bore in base plate.

Place plate T10295 on outer clutch disc "C".

Plate must not touch circlip all around.

Insert pressure unit T10285/1 with centering pin into bore of plate.
Align ATF pump on plate of pre-tensioning tool.

The pressure unit must be centrally positioned under spindle thrust piece.

Turn spindle of pre-tensioning tool downward.

The markings at inspection hole of the pressure unit must align - arrow -.

Apply Digital depth gauge VAS 6087 at upper edge of outer plate carrier "C" , as depicted in illustration.
Apply measuring tongue on outer plate and note measuring value.
Mark contact point on outer plate carrier "C".
Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.

Average over 3 measured values under load.
Release spindle and remove plate.

Fig 9: Reach With Both Hands Into Clutch "C" and Pull Plate Pack Upward Until Stop

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Reach with both hands into clutch "C" and pull plate pack upward until stop.
When disc pack is pulled up, measure distance between upper edge of outer disc carrier "C" and outer disc (2nd technician required) at one of the marked points.
Repeat measurement at 2 other marked points of outer plate.
Average over 3 measured values when plate pack is pulled up.

Determine air gap on the basis of the following calculations:

	Average of measured values under load (value 1 + value 2 + value 3): 3
	Measurement when lamella pack is pulled up (value 1 + value 2 + value 3): 3
=	Air gap

Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "C" air gap - Automatic Transmission 01V Front Wheel Drive

Transmission codes	Specified value
CJW, CJX, CJY, CJZ, DEQ, DEU, DPS, DRD, DSS, ECJ, EDE, EFR, ERY, ETK, ETL, ETU, ETV, ETW, ETZ, EYF, EZV, EZW, FAC, FAD, FATF, FAH, FAK, FED, FEE, FNL, FRT, GDE, GML	2.00 to 2.30 mm
CJQ, CJU, CJV, DCS, DDS, DDT, DES, DRF, DUL, DUM	1.63 to 1.93 mm
EBU, EBV, EBW, EBX, EBY, EBZ, EDC, EFP, EKC, EMA, EZP, EZR, EZS, EZX, EZY, EZZ, FAB, FAE, FAJ, FEV, FHV	1.25 to 1.54 mm

Clutch "C" air gap - Automatic Transmission 01V All Wheel Drive

Transmission codes	Specified value
CJR, CJS, CJT, DEW, DEX, DEY, DPT, DRK, DRN, DST, DTU, ECH, EDF, EKX, EMM, EMP, ETM, ETN, ETX, ETY, EUA, EYJ, EYK, EZB, FAN, FAP, FAQ, FAU, FAW, FAX, FAZ, FBB, FEF, FEG, FEJ, FEQ, FHD, FHG, FLC, FLV, FNM, FRU, FVE, FXL, GAK, GBH, GBJ	2.00 to 2.30 mm
CJP, DEV, DKB, DTV	1.63 to 1.93 mm
ECB, ECC, ECD, ECG, EFQ, EKD, FAL, FAM, FAR, FAS, FAV, FBA, FEP, FHF, FHH, GBF, GBG,	1.25 to 1.54 mm

If specified value is not obtained:

Fig 10: Identifying Circlip and Plate Pack

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Determine new circlip - 1 - according to the following table.

NOTE:

Disregard - 2 -.
Air gap too small: Install respectively thinner circlip.
Air gap too large: Install respectively thicker circlip.

Available circlips - thickness in mm

1.2	1.8	2.4
1.4	2.0	2.6
1.6	2.2	2.8

Check air gap of circlip again after inserting.