Removing Reverse Gear Clutch

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Fig 1: Insert Corrugated Spring Washer Into Guides Inside Transmission

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NOTE:

Refer to REPAIR INFORMATION .

Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

Transmission removed and mounted vertically to the engine/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 disc -4- and lower adjustment disc -2- and make a note of it .

NOTE:

Making a note of the old upper adjustment disc -4- and lower adjustment disc -2- will be used later when installing new adjusting discs. The measurement must be repeated if the values between the old and new adjustment discs deviate from each other .

Setting the reverse gear clutch by determining the adjustment disc:

NOTE:

The following measurements serve for the determination of the upper adjustment discs -4- and lower -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- :

Fig 2: Identifying Measurement From Input Shaft Cover Contact Surface To Corrugated Spring Washer Contact Surface

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-- Clean 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 Digital Depth Gauge 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 3 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 pre-tension clutch package, determination of dimension -A- :

Fig 3: Determine Dimension

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

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

Fig 4: Place Corrugated Spring Washer On Measuring Surface

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

-- Allocated all discs cleanly on top of each other.

Fig 5: Measure With VAS 6087 On Working Space -1- And Note Measurement

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-- Place both Ruler T40100 over the disc package.

NOTE:

Through the weight of the Ruler T40100 the air is pressed from the discs and the corrugated spring washer is subject to 2.5 kg (pre-tensioned).

-- Measure with the Digital Depth Gauge VAS6087 on the working space -1- and note the measurement "a1".

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

-- Repeat measurement on the opposite side of the disc package and note the measured value "a2".

-- Move the two Ruler T40100 by 90°.

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

-- Determine and note the average value -a- from the 4 measured values.

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

Determine dimension -A-

Fig 6: Determine Dimension

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

The height of the pre-tensioned clutch package: -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 down the measurement -A- of the pre-tensioned clutch package	= 27.98 mm

3. Measurement of the input shaft cover contact surface on the pistons of the reverse gear clutch, dimension -C- :

Fig 7: Determining Dimension

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

Fig 8: Place A Clean Outer Disc On The Removed Input Shaft

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NOTE:

The externally toothed 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 disc -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 externally toothed plate -1- laid on it with a Digital Depth Gauge VAS6087 and then make a note the measurement "D1".

Fig 9: Measuring Contact Surface On Input Shaft Cover To Externally Toothed Plate Laid On It With Digital Depth Gauge VAS 6087

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-- Repeat the measuring on different point and make a note of dimension "D2".

-- Determine and note the average value -D- from the 2 measured values.

Average: D1 + D22 = -D-

-- Remove the externally toothed plate from the input shaft and measure the thickness -d- using Digital Caliper VAS6335.

Fig 10: Removing Externally Toothed Plate From Input Shaft And Measure Thickness Using VAS 6335

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Determining dimension -C- :

Fig 11: Determining Dimension

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

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

-- Note measurement -C-.

Example
	Average value -D- = 4.51 mm + 4.49 mm2 =	4.50 mm
+	Thickness -d- of the outer discs -1-	+ 1.95 mm
=	Calculate the measurement of the input shaft cover contact surface on the pistons of the reverse gear clutch, dimension -C-	= 6.45 mm

4. Determining the thickness of both adjustment discs "E _total " :

-- Determining the thickness of the adjustment discs using the following formula using 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 disc "E₁ " and the upper adjustment disc "E₂ " according to the table below.

Thickness of both adjustment discs "E_total " in mm	Lower adjustment disc thickness "E₁ " in mm	Upper adjustment disc 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 adjustment shims .

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

-- Lower adjustment disc "E₁ " from the table: 1.90 mm

-- Upper adjustment disc "E₂ " from the table: 2.65 mm