Clutch "D/G" with freewheel, 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.
Disassembling
- Clutch "D" faces upward.
- Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".
- Twist cylinder "D/G".
- Clutch "G" faces upward (plate spring is visible).
- Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".
- Place cylinder "D/G" on thrust piece 3301/4 under shop press.
- Press plate spring down under shop press using installation bracket T10289.
- Remove circlip - 1 - , thrust washer and plate spring.
- Release shop press.
CAUTION:
Wear eye protection.
- Carefully press piston "G" out of cylinder "D/G" with compressed air.
- Press freewheel inner race - 2 - out of cylinder "D/G" - 1 - - arrow - , loosen with light taps using a plastic hammer if necessary.
- Remove cylinder "D/G" from freewheel.
- Twist cylinder "D/G".
- Cylinder "D" faces upward.
CAUTION:
Wear eye protection.
- Carefully press piston "D" out of cylinder "D/G" with compressed air.
- Disassemble freewheel:
6 - Plate spring
5 - Holding plate
4 - Freewheel with freewheel housing
3 - Rectangular rings
2 - O-rings
1 - Freewheel inner race
Assembling
CAUTION:
Before assembling, check components of freewheel, clutch "D" or clutch "G" for wear and damage →
Clutch "D/G" with freewheel .
- Replace O-rings - 2 - and - 4 - for piston "D" - 3 -.
- Press piston "D" - 3 - into cylinder "D/G" - 1 - as far as stop.
- Insert waved washer - 2 - into cylinder "D/G" - 1 -.
- Install outer plate - 3 - and coated plate - 4 - alternately.
- Install thick outer plate - 5 -.
NOTE:
- Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.
- Insert circlip - 6 -.
Adjust clutch "D" air gap
- Place clutch "D/G" on pre-tensioning tool T10285.
- Clutch "D" faces upward.
- Place plate T10293 on outer clutch disc "D".
- Plate must not touch circlip all around.
- Insert pressure unit T10285/1 with centering pin into bore of plate.
- Align clutch "D/G" 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 the pressure unit must align - arrow -.
- Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G" , as depicted in illustration.
- Apply measuring tongue on outer plate and note measuring value.
- Mark contact point on cylinder "D/G".
- 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.
- Reach with both hands into clutch "D" and pull plate pack upward until stop.
- When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer disc (2nd technician required) at one of 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 calculations:
| Average of measured values under load (value 1 + value 2 + value 3): 3 | |
| Measurement when lamella 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 "D" air gap - Automatic Transmission 01V Front Wheel Drive
| Transmission codes | Specified value |
|---|---|
| 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 | 2.29 to 2.59 mm |
| EBU, EBY, EZR, EZS, FAB, FEV | 1.92 to 2.22 mm |
| CJQ, CJU, CJW, CJX, CJY, CJZ, DCS, DDS, DDT, DEQ, DES, DEU, DPS, DRD, DRF, DUL, DUM, DSS, EFR, ETV, ETW, ETU, EZV, FAC | 2.55 to 2.85 mm |
| CJV | 2.60 to 2.92 mm |
Clutch "D" air gap - Automatic Transmission 01V All Wheel Drive
| Transmission codes | Specified value |
|---|---|
| CJP, CJR, CJS, CJT, DEV, DEW, DEX, DEY, DKB, DPT, DRK, DRN, DST, DTU, DTV, EKX, ETX, ETY, FAN, FHD | 2.55 to 2.85 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, GBG, GBH, GBJ | 2.29 to 2.59 mm |
| EFQ, FAL, FEP, GBF | 1.92 to 2.22 mm |
If specified value is not obtained:
- 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 | ||
|---|---|---|
| 2.2 | 3.0 | 3.8 |
| 2.4 | 3.2 | 4.0 |
| 2.6 | 3.4 | 4.2 |
| 2.8 | 3.6 | |
- Check air gap of circlip again after inserting.
- After having determined correct circlip, remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G" again.
- Replace O-rings - 2 - and rectangular rings - 3 - on freewheel inner race - 1 -.
4 - Freewheel with freewheel housing
5 - Holding plate
6 - Plate spring
- Before inserting, thinly coat O-rings and rectangular rings with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
- Make sure that rectangular rings are fully seated all around in freewheel inner race grooves.
- Insert freewheel inner race - 2 - with freewheel housing until stop into freewheel - 1 - using turning motions in clockwise direction - arrows -.
- Lay cylinder "D/G" - 1 - on 2 wood blocks in height of approx. 40 mm.
- Cylinder "D" faces upward.
- Insert dished washer - 2 - and holding plate - 3 - into cylinder "D/G".
- Tabs on holding plate face cylinder "D/G".
- Grasp freewheel - 4 - so that the freewheel inner race can no longer slip out and press inner race splines into splines of cylinder "D/G".
- Twist cylinder "D/G" - 1 - , while doing so secure freewheel inner race against slipping out.
- Cylinder "G" faces upward.
- Place cylinder "D/G" on thrust piece 3301/4.
- Replace O-rings - 2 - and - 4 - for piston "G" - 3 -.
- Press piston "G" - 3 - into cylinder "D/G" until stop.
- Place dished washer - 5 - and thrust washer - 6 -.
- Teeth of thrust washer must engage into splines of freewheel inner race.
7 - Circlip
- Place cylinder "D/G" on thrust piece 3301/4 under shop press.
- Press plate spring down under shop press using installation bracket T10289.
- Push thrust washer fully downward and insert circlip - 1 -.
- Make sure that circlip is seated evenly all around in groove of freewheel inner race, if necessary, press circlip into groove all around using screwdriver.
- Release shop press.
- Press plate spring down again to check if freewheel is inserted correctly.
- Thrust washer - 6 - → in previous illustration "A37-10345" must be able to move.
- Insert waved washer - 2 - into cylinder "D/G" - 1 -.
- Install outer plate - 3 - and coated plate - 4 - alternately.
- Install thick outer plate - 5 -.
NOTE:
- Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.
- Insert circlip - 6 -.
Adjust clutch "G" air gap
- Clutch "G" faces upward.
- Place clutch "D/G" on pre-tensioning tool T10285.
- Place plate T10292 on outer clutch disc "G".
- Plate must not touch circlip all around.
- Insert pressure unit T10285/1 with centering pin into bore of plate.
- Align clutch "D/G" 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 the pressure unit must align - arrow -.
- Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G" , as depicted in illustration.
- Apply measuring tongue on outer plate and note measuring value.
- Mark contact point on cylinder "D/G".
- 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.
- Reach with both hands into clutch "G" and pull plate pack upward until stop.
- When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" 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 the basis of the following calculations:
| Average of measured values under load (value 1 + value 2 + value 3): 3 | |
| Measurement when lamella 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 "G" air gap - Automatic Transmission 01V Front Wheel Drive
| Transmission codes | Specified value |
|---|---|
| CJV, CJW, CJX, CJY, CJZ, DCS, DEQ, DES, DEU, DPS, DRD, DSS, EFR, ETU, ETV, ETW, EZV, FAC | 1.52 to 1.82 mm |
| CJQ, CJU, DDS, DDT, DRF, DUL, DUM | 1.15 to 1.45 mm |
| EBW, EBX, EBZ, ECJ, EDC, EDE, EFP, EKC, EMA, ERY, ETK, ETL, ETZ, EYF, EZP, EZW, EZX, EZY, EZZ, FAB, FAE, FATF, FAH, FAJ, FAK, FED, FEE, FHV, FNL, FRT, GDE, GML | 1.79 to 2.08 mm |
| EBU, EBV, EBY, EZR, EZS, FAD, FEV | 1.33 to 1.62 mm |
Clutch "G" air gap - Automatic Transmission 01V All Wheel Drive
| Transmission codes | Specified value |
|---|---|
| CJP, CJR, CJS, CJT, DEV, DEW, DEX, DEY, DPT, DRK, DRN, DST, DTU, ECB, ECC, ECD, ECG, ECH, EDF, EKD, EKX, EMM, EMP, ETM, ETN, ETX, ETY, EUA, EYJ, EYK, EZB, FAM, FAN, FAP, FAQ, FAR, FAS, FAU, FAV, FAW, FAX, FAZ, FBA, FBB, FEF, FEG, FEJ, FHD, FHF, FHG, FHH, FLC, FLV | 1.52 to 1.82 mm |
| DKB, DTV | 1.15 to 1.45 mm |
| FEQ, FNM, FRU, FVE, FXL, GAK, GBG, GBH, GBJ | 1.79 to 2.08 mm |
| EFQ, FAL, FEP, GBF | 1.33 to 1.62 mm |
If specified value is not obtained:
- 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 | ||
|---|---|---|
| 1.8 | 2.4 | 3.0 |
| 2.0 | 2.6 | 3.2 |
| 2.2 | 2.8 | 3.4 |
- Twist clutch "D/G".
- Clutch "D" faces upward.
- Install plates for clutch "D" with newly determined circlip as follows:
- Insert waved washer - 2 - into cylinder "D/G" - 1 -.
- Install outer plate - 3 - and coated plate - 4 - alternately.
- Install thick outer plate - 5 -.
NOTE:
- Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.
- Insert circlip - 6 -.