Input shaft with 7 lining discs, adjusting with air gap determination

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NOTE:

Observe general repair notes → Repair instructions .
Rules of cleanliness for working on automatic transmissions → Rules for cleanliness when working on transmission .
All components must be cleaned thoroughly before inserting.

Clutch measurement

Fig 1: Identifying Distance Of Clutch From Upper Contact Ring Shim On Shaft & Corrugated Spring Washer Is Installed Under Disc Pack

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NOTE:

Distance - K - of the clutch from the upper contact ring shim on the shaft (Thrust plate contact surface) is determined.
The corrugated spring washer - 1 - is installed under the disc pack to perform measurements.

Fig 2: Placing Input Shaft On Assembly Tool T10219/1

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Place input shaft on assembly tool T10219/1.

Fig 3: Identifying Adjustment Discs, Lining Discs, Outer Discs And Corrugated Spring Washer

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Insert new lower adjustment disc - 1 - of same thickness as old in input shaft cylinder - A -.
Insert corrugated spring washer - 2 -.

NOTE:

The corrugated spring washer is installed at the bottom only for measurement, it is installed again at the time during assembly.

Insert alternately and with same alignment each lining disc - 3 - (7 pieces) and outer disc - 4 - (6 pieces, 1.9 mm thickness).

Fig 4: Lining Disc Alignment

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Lining disc alignment:

CAUTION:

The lining discs must be installed with the same alignment, that is the places without outside teeth - arrows - must always lie one on top of the other. Only in this way is the adjustment correct; you must mark the cylinder for correct installation, if necessary.

NOTE:

With old version of input shaft, only 6 lining discs and 5 outer discs are installed. They must be replaced with new disc pack with 7 lining discs and 6 outer discs .

Fig 5: Identifying Adjustment Discs, Lining Discs, Outer Discs And Corrugated Spring Washer

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Last, insert new upper shim - 5 - of same thickness as old in input shaft.

NOTE:

For the following measurements, all tool and component surfaces must be completely clean in order to obtain exact values.

Fig 6: Placing 4 Calipers T40101 On Upper Shim

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Place 4 calipers T40101 on upper shim.

Fig 7: Laying Ruler T40100 Centered Over Every 2 Calipers T40101

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Lay a ruler T40100 centered over every 2 calipers T40101.

Fig 8: Measuring Shim With Digital Depth Gauge VAS 6087 And Note Measurement

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Measure shim with digital depth gauge VAS 6087 and note measurement - A -.

Digital depth gauge VAS 6087 must lie flush on both rulers T40100 when measuring.

Fig 9: Measuring With Digital Depth Gauge VAS 6087 On Shaft Contact Ring (Thrust Plate Contact Surface) And Note Measurement

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Measure with digital depth gauge VAS 6087 on shaft contact ring (Thrust plate contact surface) and note measurement - B -.

Fig 10: Identifying Distance Of Clutch From Upper Contact Ring Shim On Shaft & Corrugated Spring Washer Is Installed Under Disc Pack

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Subtract both measurements "B A" , to obtain clutch distance - K -.

Clutch distance calculation - K - : "B A = K"

NOTE:

The corrugated spring washer - 1 - is installed under the disc pack to perform measurements.

Repeat measurement on opposite side of input shaft and also determine clutch distance - K -.
Insert 4 calipers T40101 and 2 rulers T40100 at 90° on input shaft and repeat measurements.
Using 4 values determined for clutch distance - K - , calculate average M _K .

Average: " (Value 1 + Value 2 + Value 3 + Value 4) : 4 = M _K "

Thrust plate measurement

First check for damage and replace, if necessary.
Rotate thrust play and lay on level and clean surface.

Fig 11: Placing 2 Calipers T40101 On Cleaned Thrust Plate Running Surface

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Place 2 calipers T40101 on cleaned thrust plate running surface.

Calipers T40101 must lie completely on clean running surfaces and must not lie on edge

Fig 12: Measuring Shim With Digital Depth Gauge VAS 6087 On Upper Running Surface And Note Measurement

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Lay rulers T40100 centered on calipers T40101.
Measure shim with digital depth gauge VAS 6087 on upper running surface and note measurement - A -.

Fig 13: Measuring With Digital Depth Gauge VAS 6087 On Lower Running Surface And Note Measurement

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Measure with digital depth gauge VAS 6087 on lower running surface and note measurement - B -.
Subtract value of both measurements "B A" to determine distance "D" of both running surfaces to thrust plate.

Thrust plate distance calculation "D" : "B A = D"

Repeat measurement on 2 additional places on thrust plate off-set at 120°.
Using these three measurements, calculate thrust plate average M _D .

Average: " (Value 1 + Value 2 + Value 3) : 3 = M _D "

Determining air play

Determine air gap on the basis of the following calculations:

	Average of thrust plate measurements " M _D " (Value 1 + Value 2 + Value 3) : 3
	Average of clutch measurements " M _K " (Value 1 + Value 2 + Value 3 + Value 4) : 4
=	Air gap

Air gap = " M _D " " M _K "

Air gap specified value: 1.8 ± 0.2 mm.

If specified value is not obtained:

A - Measured value too small:

Insert corresponding thinner adjustment disc, lower adjustment disc must also be replaced, if necessary.
Check air gap again after installing new adjustment disc → Input shaft with 7 lining discs, adjusting with air gap determination .

B - Measured value too large:

Insert corresponding thicker adjustment disc, lower adjustment disc must also be replaced, if necessary.
Check air gap again after installing new adjustment disc → Input shaft with 7 lining discs, adjusting with air gap determination .

Following adjustment discs are available:

Available adjustment discs [thickness in mm]
1.90	2.15	2.65
2.90	3.15

NOTE:

Air gap can be adjusted using upper and lower adjustment discs.

If specified value is obtained:

Fig 14: Identifying Adjustment Discs, Lining Discs, Outer Discs And Corrugated Spring Washer

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Remove all adjustment discs, lining discs, outer discs and the corrugated spring washer - 5 - , - 4 - , - 3 - , - 2 - and - 1 - from input shaft cylinder - A -.

CAUTION: This step is necessary because the corrugated spring washer - 2 - is only installed over the lower adjustment disc - 1 - in order to adjust the input shaft. When assembling the input shaft, the corrugated spring washer is installed in the upper position.

Assemble input shaft Input shaft, assembling .