Clutch "E" , 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

Fig 1: Place Clutch "E" In Mounting Device T10283

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Place clutch "E" - 1 - in mounting device T10283.

Fig 2: Identifying Circlip and Plate Pack

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Remove circlip - 1 - and remove plate pack - 2 - from cylinder "E".

Fig 3: Press Diaphragm Plate Down Under Shop Press Using Installation Bracket T10276

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Press diaphragm plate down under shop press using installation bracket T10276.
Remove circlip - 1 -.
Release shop press.

Fig 4: Clutch "E", Component Overview

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Remove diaphragm plate - 7 -.
Remove dished washer - 5 -.
Twist cylinder "E".

CAUTION: Wear eye protection.

Fig 5: Carefully Press Piston "E" Out Of Cylinder "E" With Compressed Air

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Carefully press piston "E" out of cylinder "E" with compressed air.

Assembling

CAUTION: Before assembling, check components of clutch "E" for wear and damage → Clutch "E" .

Fig 6: Clutch "E", Component Overview

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Replace O-rings - 2 - and - 4 - for piston "E" - 3 -.
Press piston "E" - 3 - into cylinder "E" - 1 - as far as stop.
Insert dished washer - 5 -.
Replace O-ring - 6 - on diaphragm plate - 7 -.

Insert diaphragm plate - 7 - into cylinder "E" - 1 -.

8 - Circlip

Fig 7: Press Diaphragm Plate Down Under Shop Press Using Installation Bracket T10276

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Press diaphragm plate down under shop press using installation bracket T10276.
Insert new circlip - 1 -.

CAUTION: Do not over-stretch circlip. After installing, check proper seating of circlip.

Release shop press.

Fig 8: Cylinder "E", Overview

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Insert waved washer - 2 - into cylinder "E" - 1 -.
Install outer plates - 3 - and coated plates - 4 - alternately.
Install thick outer plates - 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 -.

Fig 9: Adjust Clutch "E" Air Gap Using Pre-Tensioning Tool T10285

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Adjust clutch "E" air gap

Secure pre-tensioning tool T10285 with wide base in vise.
Install clutch "E" in pre-tensioning tool.

Input shaft projects through bore in base plate.

Place plate T10291 on outer clutch disc "E".

Plate must not touch circlip all around.

Insert pressure unit T10285/1 with centering pin into bore of plate.
Align clutch "E" 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 the inspection hole of the pressure unit must align - arrow -.

Insert dial gauge VAS 6080 into measuring bar VW 382/7 and tighten knurled nut.
Apply measuring bar at upper edge of cylinder "E" , as depicted in illustration.
Check whether measuring bar makes proper contact at edge of cylinder "E".
Position measuring tip on outer plate and note measuring value.

Mark exact contact point on cylinder "E".
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.

Fig 10: Reach With Both Hands Into Clutch "E" and Pull Plate Pack Upward Until Stop

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Reach with both hands into clutch "E" and pull plate pack upward until stop.
When disc pack is pulled up, measure distance between upper edge of cylinder "E" 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 "E" air gap - Automatic Transmission 01V Front Wheel Drive

Transmission codes	Specified value
CJV, CJW, CJX, CJY, CJZ, DCS, DEQ, DES, DEU, DPS, DRD, DSS, EBV, EBW, EBX, EBZ, ECJ, EDC, EDE, EFP, EFR, EKC, EMA, ERY, ETK, ETL, ETU, ETV, ETW, ETZ, EYF, EZP, EZV, EZW, EZX, EZY, EZZ, FAC, FAD, FAE, FATF, FAH, FAJ, FAK, FED, FEE, FHV, FNL, FRT, GDE, GML	1.78 to 2.08 mm
CJQ, CJU, DDS, DDT, DRF, DUL, DUM, EBU, EBY, EZR, EZS, FAB, FEV	1.41 to 1.71 mm

Clutch "E" 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, FEQ, FHD, FHF, FHG, FHH, FLC, FLV, FNM, FRU, FVE, FXL, GAK, GBG, GBH, GBJ	1.78 to 2.08 mm
DKB, DTV, EFQ, FAL, FEP, GBF	1.41 to 1.71 mm

Fig 11: Identifying Circlip and Plate Pack

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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

1.2	1.8	2.4
1.4	2.0	2.6
1.6	2.2

Check air gap of circlip again after inserting.