Input shaft, assembling
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
- Place input shaft on assembly tool T10219/1.
- 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).
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 .
- Insert determined upper adjustment disc - 4 - in input shaft cylinder - A -.
- Lastly, insert corrugated spring washer - 5 -.
- 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.
- 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.
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 .
- Install input shaft → Input shaft, removing and installing .
- 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 .