Input Shaft, Assembling

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CAUTION:

Before assembly, check for wear on transmission components. Refer to INPUT SHAFT, CHECKING FOR WEAR .

-- Replace the input shaft ball bearing. Refer to INPUT SHAFT BALL BEARING, REMOVING AND INSTALLING .

-- Adjust input shaft and determine air gap. Refer to ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY .

CAUTION:

All old, used adjustment discs, outer discs and lining discs must be replaced. They must not be reinstalled as that would not ensure the input shaft function (surface is used up).
The corrugated spring washer must be reused.

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

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

GWWA38-10082

Courtesy of AUDI OF AMERICA, LLC

-- Insert determined lower adjustment disc -1- in input shaft cylinder -A-.

Fig 2: Identifying Disc Pack

GWWA38-10080

Courtesy of AUDI OF AMERICA, LLC

-- Insert alternately and with same alignment each lining disc -2- and one externally toothed plate -3-.

Lining Disc Alignment:

Fig 3: Identifying Lining Disc Alignment

GWWA38-10057

Courtesy of AUDI OF AMERICA, LLC

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; mark the input shaft cylinder for correct installation, if necessary.

-- Insert determined upper adjustment disc -4- in input shaft cylinder -A-.

Fig 4: Identifying Disc Pack

GWWA38-10080

Courtesy of AUDI OF AMERICA, LLC

-- Lastly, insert corrugated spring washer -5-.

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

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

GWWA38-10059

Courtesy of AUDI OF AMERICA, LLC

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 pressure plate of the piston must be replaced.

-- Carefully guide thrust plate -1- with pistons -2- up over shaft -3-.

Fig 6: Guiding Thrust Plate With Pistons Up Over Shaft

GWWA38-10078

Courtesy of AUDI OF AMERICA, LLC

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

-- Push in the pressure plate with the piston evenly in the input shaft until stop.

Checking air play with the Gauge - Feeler (2 pc.) T40102.

Fig 7: Checking Air Play With Feeler Gauge T40102

GWWA38-10079

Courtesy of AUDI OF AMERICA, LLC

-- Insert both Gauge - Feeler (2 pc.) T40102 under thrust plate -A-.

-- A second technician must push thrust plate -A- down to stop -arrow 1- with Press Piece - 37mm VW416 B.

-- Guide both Gauge - Feeler (2 pc.) T40102 circularly in -direction of arrow- back and forth under thrust plate.

Both Gauge - Feeler (2 pc.) T40102 must be guided oppositely.
The Gauge - Feeler (2 pc.) T40102 must not be angled.
Entire circular area must be checked.
Both Gauge - Feeler (2 pc.) T40102 must always move freely without slightest resistance.

If the Gauge - Feeler (2 pc.) T40102 cannot be guided in -direction of arrow- without blocking:

-- Repeat the input shaft adjustment. Refer to ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY .

CAUTION:

Air play must pass check with Gauge - Feeler (2 pc.) T40102, otherwise transmission will exhibit problems after reassembly.

If the Gauge - Feeler (2 pc.) T40102 can be guided in -direction of arrow- without blocking:

-- Install input shaft cover. Refer to INPUT SHAFT COVER, REMOVING AND INSTALLING .

-- Install the input shaft. Refer to INPUT SHAFT, REMOVING AND INSTALLING

-- Install the input shaft seal. Refer to INPUT SHAFT SEAL, REPLACING .

-- Fill the Automatic Transmission Fluid (ATF) after installing the transmission. Refer to AUTOMATIC TRANSMISSION FLUID (ATF), FILLING FOR AUTOMATIC TRANSMISSION FLUID (ATF) FLUSH .