Input Shaft with 7 Lining Discs, Adjusting with Air Gap Determination
Input Shaft with 7 Lining Discs, Adjusting with Air Gap Determination
• General repair instructions, refer to => [ Repair Information ] Repair Information.
• Automatic transmission clean working conditions, refer to => [ Clean Working Conditions ] Clean Working Conditions.
• All components must be cleaned thoroughly before inserting.
Clutch measurement
• The distance - K - of the clutch from the upper contact ring shim on the shaft (thrust plate contact surface) is determined.
• The corrugated spring washer - 1 - is installed under the disc pack to perform measurements.
- Place input shaft on assembly tool (T10219/1).
- Insert new lower adjustment disc - 1 - of same thickness as old in input shaft cylinder - A -.
- Insert corrugated spring washer - 2 -.
• The corrugated spring washer is installed at the bottom only for measurement, it is installed again at the time during assembly.
- Insert alternately and with same alignment each lining disc - 3 - (7 pieces) and outer disc - 4 - (6 pieces, 1.9 mm thick).
Lining disc alignment:
• The illustration shows the lining discs with the old boot.
• 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.
• 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.
- Last, insert new upper shim - 5 - of same thickness as old in input shaft.
• For the following measurements, all tool and component surfaces must be completely clean in order to obtain exact values.
- Place 4 calipers (T40101) on upper shim.
- Lay a ruler (T40100) centered over every 2 (T40101).
- Measure shim with digital depth gauge (VAS 6087) and note measurement - A -.
• Digital depth gauge (VAS 6087) must lie flush on both (T40100) when measuring.
- Measure with (VAS 6087) on shaft contact ring (Thrust plate contact surface) and note measurement - B -.
- Subtract both measurements B - A, to obtain clutch distance - K -.
Clutch distance calculation - K - of the clutch: B - A = K
• The corrugated spring washer - 1 - is installed under the disc pack to perform measurements.
- Repeat measurement on opposite side of input shaft and also determine clutch distance - K -.
- Insert 4 (T40101) and 2 (T40100) at 90° on input shaft and repeat measurements.
- Using 4 values determined for clutch distance - K -, calculate average MK.
Average: (Value 1 + Value 2 + Value 3 + Value 4) : 4 = MK
Thrust plate measurement
- First check for damage and replace, if necessary.
- Rotate thrust play and lay on level and clean surface.
- Place 2 (T40101) on cleaned thrust plate running surface.
• Calipers (T40101) must lie completely on clean running surfaces and must not lie on edge
- Lay (T40100) centered on (T40101).
- Measure shim with (VAS 6087) on upper running surface and note measurement - A. -
- Measure with (VAS 6087) on lower running surface and note measurement - B -.
- Subtract value of both measurements B - A in order to get the distance "D" between the two areas of the thrust plate.
Thrust plate distance calculation D: B - A = D
- Repeat measurement on 2 additional places on thrust plate off-set at 120°.
- Using these three measurements, calculate thrust plate average MD.
Average: (Value 1 + Value 2 + Value 3) : 3 = MD
Determining air play
- Use the following calculation to determine air gap:
Air gap= MD - MK
Air gap specified value: 1.8 ± 0.2 mm.
If specified value is not reached:
A - Measured value too small:
- Insert corresponding thinner adjustment disc, lower adjustment disc must also be replaced, if necessary.
- Check air gap again after installing new adjustment disc. Refer to=> [ Input Shaft with 7 Lining Discs, Adjusting with Air Gap Determination ] Input Shaft with 7 Lining Discs, Adjusting with Air Gap Determination.
B - Measured value too large:
- Insert corresponding thicker adjustment disc, lower adjustment disc must also be replaced, if necessary.
- Check air gap again after installing new adjustment disc. Refer to => [ Input Shaft with 7 Lining Discs, Adjusting with Air Gap Determination ] Input Shaft with 7 Lining Discs, Adjusting with Air Gap Determination.
Following adjustment discs are available:
• Air gap can be adjusted using upper and lower adjustment discs.
If specified value is reached:
- Remove all adjustment discs, lining discs, outer discs and the corrugated spring washer - 5 -, - 4 -, - 3 -, - 2 - and - 1 - from input shaft cylinder - A -.
This step is necessary because the corrugated spring washer - 2 - is only installed over the lower adjustment disc - 1 - in order to adjust the input shaft. When assembling the input shaft, the corrugated spring washer is installed in the upper position.
- Assemble input shaft => [ Input Shaft, Assembling ] Input Shaft with 7 Lining Discs.