Adjusting Input Shaft By Determining Air Play

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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• All components must be cleaned thoroughly before inserting.

-- Place input shaft on Wishbone Rubber Mount Assembly Tool Tube T10219/1.

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

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

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

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-- Insert corrugated spring washer -2-.

-- Insert alternately and with same alignment each lining disc -3- and one externally toothed plate -4-.

Lining disc alignment:

Fig 4: Identifying Lining Disc Alignment

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

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

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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 the four Calipers T40101 on upper shim.

-- Lay a Ruler T40100 centered over every two Calipers T40101.

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

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-- Measure shim with Digital Depth Gauge VAS6087 and note measurement -A-.

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

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• The Digital Depth Gauge VAS6087 must lie flush on both Rulers T40100 when measuring.

-- Measure with Digital Depth Gauge VAS6087 on shaft contact ring (Thrust plate contact surface) and note measurement -B-.

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

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

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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Clutch distance calculation -K- of the clutch: -B - A = K-.

-- Repeat measurement on opposite side of input shaft and also determine clutch distance -K-.

-- Insert the four calipers T40101 and two 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

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

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-- First check for damage and replace, if necessary.

-- Rotate thrust play and lay on level and clean surface.

-- Place the two Calipers T40101 on the cleaned thrust plate running surface.

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

-- Place the Ruler T40100 in the center of the Caliper T40101.

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

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-- Measure the upper contact surface with Digital Depth Gauge VAS6087 and note measurement -A-.

-- Measure with Digital Depth Gauge VAS6087 on lower running surface and note measurement -B-.

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

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-- Subtract value of both measurements -B - A- = in order to get the distance -D- between the two areas of the 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

-- Use the following calculation to determine air gap:

Air gap= "M_D " - "M_K "

• Air gap specified value: 1.8 ± 0.2 mm.

If Specified Value Is Not Reached

A - Measured value too small:

-- Insert corresponding thinner adjustment disc, lower adjustment disc must also be replaced, if necessary.

-- After installing check that the air gap of the adjustment disc again. Refer to ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY .

B - Measured value too large:

-- Insert corresponding thicker adjustment disc, lower adjustment disc must also be replaced, if necessary.

-- After installing check that the air gap of the adjustment disc again. Refer to ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY .

Following adjustment discs are available:

If specified value is reached:

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-.

-- Assemble input shaft. Refer to INPUT SHAFT, ASSEMBLING .