III - Adjusting clutch clearance between -K1- and -K2- — AUDI

01N
Exploded view of components

Note:

To adjust clutch clearance, fit components without shim(s) -Item
37-116
.

Reverse gear clutch -K2-
Need not be fitted to determine shim(s)
Fit to perform control measurement

Shims
Not to be fitted for clutch clearance adjustment
1, 2 or 3 shims may be fitted

1st to 3rd gear clutch -K1-
O-ring
3rd and 4th gear clutch -K3- with turbine shaft
Thrust needle bearing with washer
Thrust needle bearing must face small input shaft
Washer must face -K3-

Gearbox housing
Planetary gearbox fitted as far as small input shaft => Assembling planetary gearbox, Page
37-116

Determining thickness of shim(s) -C-

Requirements:

Planet carrier fitted and adjusted => Assembling planetary gearbox, Page
37-116
.
For measurement purposes, gearbox housing must be positioned in repair stand such that input gear is facing downwards as shown on => Page
37-151
.

Thickness of shim(s) is governed by gap dimension "x", which is determined as follows:

x = a - b

1 -
ATF pump
2 -
Reverse gear clutch -K2-
3 -
1st to 3rd gear clutch -K1-
4 -
3rd and 4th gear clutch -K3-

C · = · Shim(s)
x · = · Gap dimension
a · = · Installation depth of clutch -K1-, determining => Page 37-154
b · = · ATF pump housing dimension, determining => Page 37-155

Determining value "a"

Place short straightedge "A" on pump flange at gearbox housing.
Press -K1- down in direction of arrow and use depth gauge "B" to measure into -K1-.

Example:
Measured value · 73.7 mm

Calculation example for value "a":

Measured value · 73.7 mm
- Straightedge · 19.5 mm
= Value "a" determined · 54.2 mm

Determining value "b"

Place paper gasket on ATF pump.
Place straightedge -B- on top of stator support (arrow) and use depth gauge -A- to measure to pump flange gasket.

Example:

Measured value · 70.5 mm

Calculation example for value "b":

Measured value · 70.5 mm
- Straightedge · 19.5 mm
= Value "b" determined · 51.0 mm

Calculation example for gap dimension "x":

Gap dimension x = a - b

= 54.2 mm - 51.0 mm = 3.2 mm

Determine shim(s) as per table. Part numbers

=> Parts List

Shim -C- table

Gap dimension "x" in mm · Shim(s) mm
... 2.54 · 1.4
2.55 ... 3.09 · 1.0 + 1.0
3.10 ... 3.49 · 1.2 + 1.2
3.50 ... 3.89 · 1.4 + 1.4
3.90 ... 4.29 · 1.6 + 1.6
4.30 ... 4.69 · 1.8 + 1.8
4.70 ... 5.04 · 1.2 + 1.2 + 1.6
5.05 ... 5.25 · 1.2 + 1.2 + 1.8

The shims have various thicknesses:

Blue / Green / White / Black / Grey · = / = / = / = / = · 1.0 mm / 1.2 mm / 1.4 mm / 1.6 mm / 1.8 mm

Perform clutch clearance check measurement after installing ATF pump.

Check measurement (clutch clearance)

Clutch clearance cannot be measured until ATF pump has been installed.
Reverse gear clutch -K1- must have been fitted.

Attach dial gauge holder to gearbox housing and position dial gauge with 1 mm initial tension on turbine shaft.

Note:

The gearbox must be moved to its installation position so that the turbine shaft can be moved.

Pull out and push in turbine shaft (resistance can be felt) and take clearance reading on dial gauge.

Clearance: min. = 0.5 mm; max. = 1.2 mm