Clutch "B" , disassembling and assembling

Fig 1: Circlip And Disc Pack From Cylinder "B"

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Twist clutch "B" and place on workbench.
Remove circlip - 1 - and remove disc pack - 2 - from cylinder "B".

Fig 2: Dished Washer, Installation Bracket T10277 And Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press dished washer down under shop press using installation bracket T10277.
Remove circlip - 1 -.

Fig 3: Cylinder "B", O-Rings For Piston "B", Gasket, Dished Washer And Retaining Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove retaining ring - 6 -.
Remove dished washer - 5 -.

CAUTION: Wear protective glasses.

Fig 4: Pressing Piston "B" Out Of Cylinder "B" With Compressed Air

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully press piston "B" out of cylinder "B" with compressed air, to do so plug free oil bore using finger.

CAUTION: Check individual components of clutch "B" for wear and damage → Clutch "C" with sun shaft .

Fig 5: Cylinder "B", O-Rings For Piston "B", Gasket, Dished Washer And Retaining Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace O-rings - 2 - for piston "B" - 3 -.
Replace gasket - 4 - in piston "B".
Press piston "B" - 3 - into cylinder "B" - 1 - until stop.
Replace dished washer - 5 - and place dished washer as well as retaining ring - 6 -.

Fig 6: Dished Washer, Installation Bracket T10277 And Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press dished washer down under shop press using installation bracket T10277.
Insert circlip - 1 -.

NOTE:

Do not over-stretch circlip. After installing, check proper seating of circlip.

Release shop press.

Fig 7: Cylinder "B", Wave Washer, Outer Plate, Coated Plate And Thick Outer Plate

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Insert wave washer - 2 - into cylinder "B" - 1 -.
Install outer plate - 3 - and coated plate - 4 - alternately.
Install thick outer plate - 5 -.

Smooth side faces last coated plate.

Insert circlip - 6 -.

Fig 8: Adjusting Air Gap Clutch "B"

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adjust air gap clutch "B"

Place cylinder "B" on pre-tensioning tool T10285.
Position plate T10281 on outer clutch plate "B".

Plate must not touch circlip.

Insert pressure unit T10285/1 with centering pin into bore of plate.
Align cylinder "B" 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 "B" , as depicted in illustration.
Check whether measuring bar makes proper contact at edge of cylinder "B".
Position measuring tip on outer plate and note measuring value.

Mark exact contact point on cylinder "B".
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.

Fig 9: Pulling Disc Pack Upward Using Hands

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Reach with both hands into clutch "B" and pull disc pack upward until stop.
When disc pack is pulled up, measure distance between upper edge of cylinder "B" 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.

Air gap clutch "B" for transmission with code letters CUE, DPZ, DSL, DSM, DTD, DTE, DYM, ECX:

1.95 to 2.25 mm.

Air gap clutch "B" for transmission with code letters ECY, ECZ and the following:

2.15 to 2.45 mm.

If specified value is not obtained:

Fig 10: Circlip And Disc Pack From Cylinder "B"

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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
2.6	3.4	4.2
2.8	3.6	4.4
3.0	3.8	4.6
3.2	4.0

Check air gap of circlip again after inserting.