Forward Clutch: Reassembly
- Lubricate piston sealing lips with ATF. Install piston into drum using twisting motion. On all models except E-Mode, install diaphragm spring, with convex side toward piston into clutch drum. Install retaining snap ring.
- With snap ring installed, diaphragm spring should be lightly tensioned; if not, replace spring. Install thrust plate into drum. If one side of thrust plate is chamfered, install chamfered side toward diaphragm spring.
- On E-Mode models, install spring support ring and spring retaining ring. Springs must be installed with small diameter toward spring plate. Install spring plate and circlip. Install spring and spring washer with convex side toward piston. Install thrust plate.
- On all models, install one lined (internally splined) clutch plate. Use only lined plates with identifications grooves. Install forward planetary ring gear so that short splines beneath its retaining ridge are engaged in lined clutch plate. Install remaining clutch plates starting with steel (externally splined) clutch plate and alternating lined and steel plates until all clutch plates are installed. See FORWARD CLUTCH PLATES table.
- Install pressure plate and retaining snap ring into clutch drum. Position dial indicator on clutch assembly so that indicator pointer contacts pressure plate. Zero indicator.
- Measure forward clutch end play by moving forward planetary ring gear up and down so that dial indicator will read play between pressure plate and snap ring. See Fig 1 .
- Forward clutch end play should be .020-.035" (.50-.90 mm) on all models. If not, replace pressure plate (except E-Mode models) with one of correct thickness to bring play within specification. After correct pressure plate has been installed, recheck end play.
- Forward clutch pressure plates are available in thicknesses of 2.3-3.9 mm with .4 mm increments for all 087 models except for those in Quantum models. Quantum 087 models use pressure plates ranging from 6.0-7.6 mm with .4 mm increments.
- On 5000S 087 models, both 2.3-3.9 mm and 6.0-7.6 mm ranges are available. On 089 models forward clutch pressure plates are available in thicknesses of 6.0-7.6 mm with .4 mm increments.
- All E-Mode transaxles adjust forward clutch end play by replacing snap ring. Snap rings are available in 1.5, 1.7, 2.0, 2.3, 2.5, 2.9, 3.2, and 3.5 mm.
FORWARD CLUTCH PLATES
| Application | Steel Plates | Lined Plates | |
|---|---|---|---|
| 087 Model | |||
| Coupe GT, 4000S, 4000S Quattro & Quantum | 3 | 4 | |
| 5000S & 944 | 4 | 5 | |
| 089 Model | |||
| Coupe GT, 4000S, 4000S Quattro & Quantum | 2 | 3 | |
| All E-Mode Models | 3 | 4 | |