Clutch D/G With Freewheel

Clutch D/G with Freewheel

Disassembling

• Clutch "D" faces upward.

- Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".

- Twist cylinder "D/G".

• Clutch "G" faces upward (plate spring is visible).

- Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".

- Place cylinder "D/G" on thrust piece (3301/4) under shop press.

- Press plate spring down under shop press using installation bracket (T10289).

- Remove circlip - 1 -, thrust washer and plate spring.

- Release shop press.

CAUTION!
Wear eye protection.

- Carefully press piston "G" out of cylinder " D/G" with compressed air.

- Press freewheel inner race - 2 - out of cylinder " D/G" - 1 - - arrow -, loosen with light taps using a plastic hammer if necessary.

- Remove cylinder "D/G" from freewheel.

- Twist cylinder "D/G".

• Cylinder "D" faces upward.

CAUTION!
Wear eye protection.

- Carefully press piston "D" out of cylinder " D/G" with compressed air.

- Disassemble freewheel:

6 Plate spring
5 Holding plate
4 Freewheel with freewheel housing
3 Rectangular rings
2 O-rings
1 Freewheel inner race

Assembling

CAUTION!
Before assembling, check components of freewheel, clutch "D " or clutch "G" for wear and damage. Refer to => [ Clutch D/G, with Freewheel ] Clutch D/G, With Freewheel.

- Replace O-rings - 2 - and - 4 - for piston "D" - 3 -.

- Press piston "D" - 3 - into cylinder " D/G" - 1 - as far as stop.

- Insert waved washer - 2 - into cylinder "D/G " - 1 -.

- Install outer plate - 3 - and coated plate - 4 - alternately.

- Install thick outer plate - 5 -.

• Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

- Insert circlip - 6 -.

Adjust clutch "D" air gap

- Place clutch "D/G" on pre-tensioning tool (T10285).

• Clutch "D" faces upward.

- Place plate (T10293) on outer clutch disc "D".

• Plate must not touch circlip all around.

- Insert pressure unit (T10285/1) with centering pin into bore of plate.

- Align clutch "D/G" on plate of pre-tensioning tool.

• The pressure unit must be centrally positioned under spindle thrust piece.

- Turn spindle of pre-tensioning tool downward.

• The markings at inspection hole of the pressure unit must align - arrow -.

- Apply Digital depth gauge (VAS 6087) at upper edge of cylinder "D/G", as depicted in illustration.

- Apply measuring tongue on outer plate and note measuring value.

- Mark contact point on cylinder "D/G".

- Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.

- Average over 3 measured values under load.

- Release spindle and remove plate.

- Reach with both hands into clutch "D" and pull plate pack upward until stop.

- When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer disc (2nd technician required) at one of marked points.

- Repeat measurement at 2 other marked points of outer plate.

- Average over 3 measured values when plate pack is pulled up.

- Determine air gap on basis of the following calculations:

- Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "D" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "D" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained:

- Determine new circlip - 1 - according to the following table.

• Disregard - 2 -.

• Air gap too small: Install respectively thinner circlip.

• Air gap too large: Install respectively thicker circlip.

- Check air gap of circlip again after inserting.

- After having determined correct circlip, remove circlip - 1 - and remove plate pack - 2 - from cylinder " D/G" again.

- Replace O-rings - 2 - and rectangular rings - 3 - on freewheel inner race - 1 -.

4 Freewheel with freewheel housing
5 Holding plate
6 Plate spring

- Before inserting, thinly coat O-rings and rectangular rings with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.

- Make sure that rectangular rings are fully seated all around in freewheel inner race grooves.

- Insert freewheel inner race - 2 - with freewheel housing until stop into freewheel - 1 - using turning motions in clockwise direction - arrows -.

- Lay cylinder "D/G" - 1 - on 2 wood blocks in height of approx. 40 mm.

• Cylinder "D" faces upward.

- Insert dished washer - 2 - and holding plate - 3 - into cylinder "D/G".

• Tabs on holding plate face cylinder "D/G".

- Grasp freewheel - 4 - so that the freewheel inner race can no longer slip out and press inner race splines into splines of cylinder " D/G".

- Twist cylinder "D/G" - 1 -, while doing so secure freewheel inner race against slipping out.

• Cylinder "G" faces upward.

- Place cylinder "D/G" on thrust piece (3301/4).

- Replace O-rings - 2 - and - 4 - for piston "G" - 3 -.

- Press piston "G" - 3 - into cylinder " D/G" until stop.

- Place dished washer - 5 - and thrust washer - 6 -.

• Teeth of thrust washer must engage into splines of freewheel inner race.

7 Circlip

- Place cylinder "D/G" on thrust piece (3301/4) under shop press.

- Press plate spring down under shop press using installation bracket (T10289).

- Push thrust washer fully downward and insert circlip - 1 -.

- Make sure that circlip is seated evenly all around in groove of freewheel inner race, if necessary, press circlip into groove all around using screwdriver.

- Release shop press.

- Press plate spring down again to check if freewheel is inserted correctly.

• Thrust washer - 6 - => in previous illustration " A37-10345" must be able to move.

- Insert waved washer - 2 - into cylinder "D/G " - 1 -.

- Install outer plate - 3 - and coated plate - 4 - alternately.

- Install thick outer plate - 5 -.

• Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

- Insert circlip - 6 -.

Adjust clutch "G" air gap

• Clutch "G" faces upward.

- Place clutch "D/G" on pre-tensioning tool (T10285).

- Place plate (T10292) on outer clutch disc "G".

• Plate must not touch circlip all around.

- Insert pressure unit (T10285/1) with centering pin into bore of plate.

- Align clutch "D/G" on plate of pre-tensioning tool.

• The pressure unit must be centrally positioned under spindle thrust piece.

- Turn spindle of pre-tensioning tool downward.

• The markings at inspection hole of the pressure unit must align - arrow -.

- Apply Digital depth gauge (VAS 6087) at upper edge of cylinder "D/G", as depicted in illustration.

- Apply measuring tongue on outer plate and note measuring value.

- Mark contact point on cylinder "D/G".

- Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.

- Average over 3 measured values under load.

- Release spindle and remove plate.

- Reach with both hands into clutch "G" and pull plate pack upward until stop.

- When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer disc (2nd technician required) at one of the marked points.

- Repeat measurement at 2 other marked points of outer plate.

- Average over 3 measured values when plate pack is pulled up.

- Determine air gap on the basis of the following calculations:

- Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "G" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "G" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained:

- Twist clutch "D/G".

• Clutch "D" faces upward.

- Install plates for clutch "D" with newly determined circlip as follows:

- Insert waved washer - 2 - into cylinder "D/G " - 1 -.