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Home >> Porsche >> 1985 >> 944 Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - A/T - AUDI 087, 087E, 089 >> Component Disassembly & Reassembly >> Forward Clutch >> Reassembly

Forward Clutch: Reassembly

  1. Lubricate piston sealing lips with ATF. Install piston into drum using twisting motion. On all series except E-Mode, install diaphragm spring, with convex side toward piston, into clutch drum. Install retaining snap ring.
  2. 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
    Fig 1: Exploded View of Standard Forward Clutch Assembly
    G96I15048Courtesy of AUDI OF AMERICA, INC.
    Fig 2: Exploded View of E-Mode Forward Clutch Assembly
    G00153643Courtesy of AUDI OF AMERICA, INC.
    Fig 3: Forward Clutch Lined Plate
    G00308795Courtesy of AUDI OF AMERICA, INC.

    Soak new friction plates in ATF for 15 minutes before installing.

  3. On E-Mode series, install spring support ring and spring retaining ring. Springs must be installed with small diameter toward spring plate. Install spring plate and snap ring, Install spring and spring washer with convex side toward piston. Install thrust plate.
  4. On all series, install one lined (internally splined) clutch plate. Use only lined plates with identification grooves. See Fig 3 . Install forward planetary ring gear so that short splines beneath its retaining ridge are engaged in lined clutch plate.
  5. Install remaining clutch plates starting with steel (externally splined) clutch plate and alternating lined and steel plates until all clutch plates are installed. See FOWARD CLUTCH PLATES  .
  6. 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.
  7. 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 4 .
    Fig 4: Measuring Forward Clutch End Play
    G96J15049Courtesy of AUDI OF AMERICA, INC.
    FOWARD CLUTCH PLATES

    Application Steel Plates Lined Plates
    087 Model
    Coupe, 4000 & Quantum 3 4
    5000 & 944 4 5
    089 Model
    Coupe, 4000 & Quantum 2 3
    All E-Mode Models 3 4
  8. Forward clutch end play should be .020-.035" (.50-.90 mm) on all series. If not, replace pressure plate (except E-Mode series) with one of correct thickness to bring play within specification. After correct pressure plate has been installed, recheck end play.
  9. Forward clutch pressure plates are available in thicknesses of 2.3-3.9 mm with .4 mm increments for all 087 series except for those in Quantum vehicles. Quantum 087 series use pressure plates ranging from 6.0-7.6 mm with .4 mm increments.
  10. On 5000S (087) series, both 2.3-3.9 mm and 6.0-7.6 mm ranges are available. On 089 series in Coupe GT, 4000S, 4000S Quattro and Quantum vehicles, forward clutch pressure plates are available in thicknesses of 6.0-7.6 mm with .4 mm increments.
  11. All E-Mode transaxles adjust forward clutch end play by replacing snap ring. Snap rings are available in sizes 1.5 to 3.5 mm.
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