Clutch "A" , disassembling and assembling
- Place clutch "A" - 1 - in mounting device T10282.
- Remove circlip - 1 - and remove disc pack - 2 - from cylinder "A".
- Press diaphragm plate down under shop press using installation bracket T10276.
- Remove circlip - 1 -.
- Remove diaphragm plate - 7 -.
- Remove dished washers - 5 -.
NOTE:
- Dependent on construction version, 1 or 2 dished washers - 5 - are installed. When installing, use same quantity of dished washers as were found when removed.
- Twist cylinder "A".
CAUTION:
Wear protective glasses.
- Carefully press piston "A" out of cylinder "A" with compressed air, to do so plug free oil bore using finger.
CAUTION:
Check individual components of clutch "A" for wear and damage →
Clutch "A" .
- Replace O-rings - 2 - and - 4 - for piston "A" - 3 -.
- Press piston "A" - 3 - into cylinder "A" - 1 - until stop.
- Insert dished washers - 5 -.
NOTE:
- Dependent on construction version, 2 dished washers - 5 - are installed. When installing, use same quantity of dished washers as were found when removed.
- Replace O-ring - 6 - in diaphragm plate - 7 -.
- Insert diaphragm plate - 7 -.
8 - Circlip
- Press diaphragm plate down under shop press using installation bracket T10276.
CAUTION:
Do not over-stretch circlip.
- Replace circlip - 1 - and install carefully.
CAUTION:
After installing, check proper seating of circlip:
- Circlip must no longer be moved and must contact base of groove.
- Insert wave washer - 2 - into cylinder "A" - 1 -.
- Install outer plates - 3 - (6x) and coated plates - 4 - (6x) alternately.
- Install thick outer plate - 5 -.
- Smooth side faces last coated plate.
- Insert circlip - 6 -.
Adjust air gap clutch "A"
- Secure pre-tensioning tool T10285 with wide base in vise.
- Install cylinder "A" in pre-tensioning tool.
- Input shaft projects through bore in base plate.
- Position plate T10279 on outer clutch plate "A".
- Plate must not touch circlip all around.
- Insert pressure unit T10285/1 with centering pin into bore of plate.
- Align cylinder "A" 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 the inspection hole of the pressure unit must align - arrow -.
- Insert dial gauge VAS 6080 into measuring bar VW 382/7 and tighten knurled nut.
- Apply measuring bar at upper edge of cylinder "A" , as depicted in illustration.
- Check whether measuring bar makes proper contact at edge of cylinder "A".
- Position measuring tip on outer plate and note measuring value.
- Mark exact contact point on cylinder "A".
- 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 "A" and pull disc pack upward until stop.
- When disc pack is pulled up, measure distance between upper edge of cylinder "A" and outer plate (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 disc pack is pulled up.
- Determine air gap on the basis of the following calculations:
| Average of measured values under load (value 1 + value 2 + value 3): 3 | |
| Measurement when disc pack is pulled up (value 1 + value 2 + value 3): 3 | |
| = | Air gap |
- Subtract average of measured values when disc pack is pulled up from average of measured values under load.
- Specified value: 1.95 to 2.25 mm.
If specified value is not obtained:
- Determine new circlip - 1 -.
NOTE:
- Disregard - 2 -.
- Measured value too small: Install respectively thinner circlip.
- Measured value too large: Install respectively thicker circlip.
The following circlips are available:
| Available circlips in mm | ||
| 1.8 | 2.6 | 3.4 |
| 2.0 | 2.8 | 3.6 |
| 2.2 | 3.0 | |
| 2.4 | 3.2 | |
- Check air gap of circlip again after inserting.