Removing Reverse Gear Clutch

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NOTE:

Refer to REPAIR INFORMATION .

Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

Transmission removed and mounted vertically to the engine and transmission holder. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

-- Remove the input shaft. Refer to INPUT SHAFT, REMOVING AND INSTALLING .

-- Remove the reverse gear clutch and corrugated spring washer -1 through 5- from the transmission.

-- Measure The Upper Adjustment Plate -4- And Lower Adjustment Plate -2- And Note The Measurements.

NOTE:

Recording the measurements of the old upper adjustment plate -4- and lower adjustment plate -2- will be used later when installing new adjusting plates. If the values of the old and new adjustment plates deviate too much from each other, then the measurement must be repeated.

Setting The Reverse Gear Clutch By Determining The Adjustment Plates:

NOTE:

The following measurements serve for the determination of the upper adjustment plate -4- and lower plate -2- for the setting of the reverse gear clutch.

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

1. Measurement From The Input Shaft Cover Contact Surface To The Corrugated Spring Washer Contact Surface -B- :

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-- Clean contact and sealing surfaces on the transmission housing, completely remove remaining seals.

-- Measure from the input shaft cover contact surface to the corrugated spring washer contact surface inside the transmission housing using :VAS6087 .

-- Make a note of dimension "B1".

-- Repeat measurement on two different points and note the measured values "B2" and "B3".

-- Determine and note the average value -B- from the three measured values.

Average: B1 + B2 + B33 = dimension -B-

-- Make of note of dimension -B-.

Example:

29.0 mm + 28.9 mm + 29.0 mm3 = 28.97 mm

In the example, dimension -B- = 28.97 mm.

2. Measurement Of The Pretensioned Clutch Package, Determination Of Dimension -A- :

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The corrugated spring washer -2- is installed under the clutch plate pack to perform measurements.
Use a clean and flat measuring surface as a backing -1-. In the following description, the :T10285 is used.

-- Place the corrugated spring washer -A- first on the measuring surface -1-.

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-- Then, alternating with the same direction for each lining plate -C- (quantity: 6) and place an outer clutch plate -B- (quantity: 5) on the corrugated spring washer.

-- Align all clean plates on top of each other.

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-- Place both :T40100 over the clutch plate pack.

NOTE:

Due to the weight of the :T40100 , the air is pressed out of the discs and the corrugated spring washer is loaded (pretensioned) to the specified 2.5 kg.

-- Measure with the :VAS6087 on the work surface -1- and note the measurement "a1".

The :VAS6087 must lie flush on both :T40100 when measuring.

-- Repeat the measurement on the opposite side of the clutch plate pack and note the measured value "a2".

-- Offset the two :T40100 by 90°.

-- Repeat the measurements and make a note of the values "a3" and "a4".

-- Calculate and note the average value -a- from the four measured values.

Average: a1 + a2 + a3 + a44 = -a-

Determining dimension -A- :

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-- Measure and note the thickness -b- of the :T40100 .

The height of the pretensioned clutch package is -a- - -b- = dimension -A-

-- Make a note of dimension -A-.

Example
	Average value made with the depth gauge 35.45 mm + 35.46 mm + 35.42 mm + 35.47 mm4 = -a-	35.45 mm
-	Ruler :T40100 thickness -b-	- 7.47 mm
=	Note the measurement -A- of the pretensioned clutch package	= 27.98 mm

3. Measurement Of The Input Shaft Cover Contact Surface On The Pistons Of The Reverse Gear Clutch, Dimension -C- :

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-- Place a clean outer clutch plate -1- on the removed input shaft.

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NOTE:

The outer clutch plate -1- is placed on the reverse gear clutch piston so that a correct measurement can be performed on the highest position of the piston. The thickness -d- of the outer clutch plate -1- will be subtracted later to determine the amount of the piston.

-- Measure from the contact surface -2- on the input shaft cover to the positioned outer clutch plate -1- with a :VAS6087 and then note the measurement "D1".

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-- Repeat the measurement at another offset point and note dimension "D2".

-- Calculate and note the average -D- of the two measured values.

Average: D1 + D22 = -D-

-- Remove the outer clutch plate from the input shaft and measure the thickness -d- using the :VAS6335 .

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Determining dimension -C- :

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Calculate dimension -C- of the input shaft cover contact surface on the pistons of the reverse gear clutch:

-D- + -d- = dimension -C-

-- Note dimension -C-.

Example
	Average -D- = 4.51 mm + 4.49 mm2 =	4.50 mm
+	Thickness -d- of the outer clutch plate -1-	+ 1.95 mm
=	Dimension -C- from the input shaft cover contact surface on the reverse gear clutch pistons	= 6.45 mm

4. Determining the Thickness of Both Adjustment Plates "E_total " :

-- Determining the thickness of the adjustment plates using the following formula with dimensions "A", "B" and "C" and a constant air gap of 3.0 mm:

"B" + "C" - "A" - 3.0 mm = "E_total "

-- Select the lower adjustment plate "E₁ " and the upper adjustment plate "E₂ " according to the table. Refer to REVERSE GEAR CLUTCH, REMOVING AND INSTALLING, SELECTING ADJUSTMENT PLATES .

Thickness of Both Adjustment Plates "E _total " in mm	Lower Adjustment Plate Thickness "E₁ " in mm	Upper Adjustment Plate Thickness "E₂ " in mm
3.916 to 4.165	1.90	2.15
4.166 to 4.435	2.15	2.15
4.436 to 4.675	1.90	2.65
4.676 to 4.925	1.90	2.90
4.926 to 5.165	1.90	3.15
5.166 to 5.425	2.15	3.15
5.426 to 5.675	2.65	2.90
5.676 to 5.925	2.65	3.15
5.926 to 6.175	2.90	3.15
6.176 to 6.400	3.15	3.15

NOTE:

Allocate the shims. Refer to the Parts information.

Example:

The following values are found in the example:

Dimension "A" = 27.98 mm
Dimension "B" = 28.97 mm
Dimension "C" = 6.45 mm
Constant air gap = 3.0 mm

"B" + "C" - "A" - 3.0 mm = "E_total "

28.97 mm + 6.45 mm - 27.98 mm - 3.0 mm = 4.44 mm

"E_total " = 4.44 mm

-- Determine lower adjustment plate "E₁ " from the table: 1.90 mm

-- Determine upper adjustment plate "E₂ " from the table: 2.65 mm