Clutch "F" , 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.

Fig 1: Identifying Circlip and Plate Pack

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Disassembling

Rotate clutch - F -.
Remove circlip - 1 - and remove plate pack - 2 - from cylinder "F".

Fig 2: Press 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.
Remove thrust piece and plate spring.

Position cylinder "F" on clutch "D/G" with freewheel.

CAUTION: Wear eye protection.

Fig 3: Carefully Press Piston "F" With Compressed Air Out Of Cylinder "F"

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Carefully press piston "F" with compressed air out of cylinder "F" as shown in illustration.

Assembling

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

Fig 4: Clutch "F", Assembling, Overview

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Replace O-rings - 2 - and - 4 - for piston "F" - 3 -.
Press piston "F" - 3 - into cylinder "F" - 1 - as far as stop.
Place thrust piece - 5 -.
Position plate spring - 6 -.

7 - Split retaining ring

Fig 5: Press Plate Spring Down Under Shop Press Using Installation Bracket T10289

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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 6: Cylinder "F" Component, Overview

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Insert waved washer - 2 - into cylinder "F" - 1 -.
Install outer plate - 3 - and coated plate - 4 - alternately.

NOTE:

Ensure rounded edges of last outer clutch disc faces toward lining disc - 4 - and not toward circlip - 5 -. This improves circlip contact surface.

Insert circlip - 5 -.

Adjust clutch "F"

Fig 7: Adjusting Clutch "F" "Air Gap"

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Place clutch "F" on pre-tensioning tool T10285.
Place plate T10292 on outer clutch disc "F".

Plate must not touch circlip all around.

Insert pressure unit T10285/1 with centering pin into bore of plate.
Align clutch "F" 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 pressure unit must align - arrow -.

Apply Digital depth gauge VAS 6087 at upper edge of cylinder "F" , as depicted in illustration.
Apply measuring tongue on outer plate and note measuring value.
Mark contact point on cylinder "F".
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 8: Reach With Both Hands Into Clutch "F" and Pull Plate Pack Upward Until Stop

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Reach with both hands into clutch "F" and pull plate pack upward until stop.
When disc pack is pulled up, measure distance between upper edge of cylinder "F" 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 basis of the following calculus:

	Average of measured values under load (value 1 + value 2 + value 3): 3
	Measurement when plate 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 "F" air gap - Automatic Transmission 01V Front Wheel Drive

Transmission codes	Specified value
CJQ, CJU, DDS, DDT, DRF, DUL, DUM	1.50 to 1.82 mm
CJV, CJW, CJX, CJY, CJZ, DEQ, DCS, DES, DEU, DPS, DRD, DSS, EFR, ETU, ETV, ETW, EZV, FAC	1.90 to 2.20 mm
EBU, EBY, EZR, EZS, FAB, FEV	1.81 to 2.10 mm
EBV, EBW, EBX, EBZ, ECJ, EDC, EDE, EFP, EKC, EMA, ERY, ETK, ETL, ETZ, EYF, EZP, EZW, EZX, EZY, EZZ, FAD, FAE, FATF, FAH, FAJ, FAK, FED, FEE, FHV, FNL, FRT, GDE, GML	2.26 to 2.55 mm

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

Transmission codes	Specified value
DKB, DTV	1.50 to 1.82 mm
CJP, CJR, CJS, CJT, DEV, DEW, DEX, DEY, DPT, DRK, DRN, DST, DTU, EKX, ETX, ETY, FAN, FHD	1.90 to 2.20 mm
EFQ, FAL, FEP, GBH	1.81 to 2.10 mm
ECB, ECC, ECD, ECG, ECH, EDF, EKD, EMM, EMP, ETM, ETN, EUA, EYJ, EYK, EZB, FAM, FAP, FAQ, FAR, FAS, FAU, FAV, FAW, FAX, FAZ, FBA, FBB, FEF, FEG, FEJ, FEQ, FHF, FHG, FHH, FLC, FLV, FNM, FRU, FVE, FXL, GAK, GBF, GBG, GBJ	2.26 to 2.55 mm

If specified value is not obtained:

Fig 9: Identifying Circlip and Plate Pack

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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.