Input shaft, assembling

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CAUTION: Before assembly, check for wear on transmission components.

Replace ball bearing in input shaft cover → Ball bearing in input shaft cover, replacing .
Adjust input shaft and determine air gap → Input shaft with 7 lining discs, adjusting with air gap determination

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

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Place input shaft on assembly tool T10219/1.

Fig 2: Identifying Disc Pack

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Insert determined lower adjustment disc - 1 - in input shaft cylinder - A -.
Insert alternately and with same alignment each lining disc - 2 - (7 pieces) and outer disc - 3 - (6 pieces, 1.9 mm thickness).

Fig 3: Lining Disc Alignment

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Lining disc alignment:

CAUTION:

The lining discs must be installed with the same alignment, that is the places without outside teeth - arrows - must always lie one on top of the other. Only in this way is the adjustment correct; you must mark the cylinder for correct installation, if necessary.

NOTE:

With old version of input shaft, only 6 lining discs and 5 outer discs are installed. They must also be replaced with new disc pack with 7 lining discs and 6 outer discs .

Fig 4: Identifying Disc Pack

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Insert determined upper adjustment disc - 4 - in input shaft cylinder - A -.
Lastly, insert corrugated spring washer - 5 -.

Fig 5: Inner Running And Sealing Surfaces Of Thrust Plate And Pistons

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Press piston - 1 - into stop on thrust plate - 2 -.

CAUTION:

The inner running and sealing surfaces - arrow A - of the thrust plate and pistons - arrow C - must not touch shaft during removal and installation.
The running and contact surfaces must not show the smallest signs of damage such as scratches or grooves as a result of removing or installing.
If damaged, the thrust plate or pistons must be replaced.

Fig 6: Guiding Thrust Plate With Pistons Up Over Shaft

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Carefully guide pressure plate - 1 - with pistons - 2 - down over shaft - 3 -.

Inner running surfaces of thrust plate - 1 - and pistons - 2 - must not touch shaft.

Press thrust plate with pistons uniformly into input shaft up to stop.

Fig 7: Checking Air Play With Feeler Gauge T40102

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Checking air play with feeler gauge T40102

Insert both feeler gauges T40102 under thrust plate - A -.
A second technician must push thrust plate - A - down to stop - arrow 1 - with Tube VW 416 B.
Guide both feeler gauges T40102 circularly in direction of - arrow - back and forth under thrust plate.

Both feeler gauges T40102 must be guided oppositely.
Feeler gauges T40102 must not be angled.
Entire circular area must be checked.
Both feeler gauges T40102 must always move freely without slightest resistance.

If feeler gauges T40102 cannot be guided in direction of - arrow - without blocking:

Repeat input shaft adjustment → Input shaft with 7 lining discs, adjusting with air gap determination .

CAUTION: Air play must pass check with feeler gauges T40102 , otherwise transmission will exhibit problems after reassembly.

If feeler gauges T40102 can be guided in direction of - arrow - without blocking:

Install input shaft cover → Torsen differential cover, removing and installing .

Fig 8: Removing Bolts

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Install input shaft → Input shaft, removing and installing .

Fig 9: Sliding Shaft Seal Onto Input Shaft With Open Side Facing Transmission

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Install input shaft seal - A - → Input shaft seal, replacing .
Fill with ATF → ATF, filling for ATF flushing process .

CAUTION:

The Multitronic 01J or 0AN transmission requires a different ATF than shift automatics. Only ATF for CVT transmission which can be obtained as replacement part must be used in planetary gearing .
Flush ATF after installing transmission → ATF flushing process .