Clutch - Direct Shift Automatic Transmission 02e (awd) (roadster) Audi TT 8J

MULTI-PLATE CLUTCH, SERVICING OVERVIEW

1. The clutch of the S-Tronic transmission 02E has 2 clutch disks and is also called a "multi-plate clutch" because of this. The exterior, larger clutch disc is called "K 1" (clutch 1) and shifts the reverse gear and the gears 1, 3 and 5. The inner, smaller "K 2" (clutch 2) shifts the gears 2, 4 and 6.
2. Because all parts of the multi-plate clutch were balanced together during manufacture, assembly work requires special caution. The location of the parts to one another changes during removal and installation, imbalances result. These impair the shift function and shorten the service life.

Replacement Part Package

Scheme 545

1. Multi-Plate Clutch With locking ring CAUTION: Risk of discs in multi-plate clutch slipping. Do not disassemble the multi-plate clutch at this time. If the drive plate (upper section of multi-plate clutch) comes out of the outer clutch pack carrier teeth, the plates can slip. The multi-plate clutch can no longer be adjusted correctly. In the replacement part package, the drive plate is not secured with the large circlip but rather only sits "taut" in the multi-plate clutch. Removing and installing, refer to «MULTI-PLATE CLUTCH»(/audi/tt/8j-2006-2010/remont/automatic-trans/#clutch-direct-shift-automatic-transmission-02e-awd-roadster__multi-plate-clutch)
2. Circlips Quantity: 10, different thicknesses for adjusting multi-plate clutch Determine thickness when installing multi-plate clutch «MULTI-PLATE CLUTCH, ADJUSTING (DETERMINE CIRCLIP THICKNESS)»(/audi/tt/8j-2006-2010/remont/automatic-trans/#clutch-direct-shift-automatic-transmission-02e-awd-roadster)
3. Clutch End Cover
4. Shaft Ring

Individual Parts of Disassembled Multi-Plate Clutch

Scheme 546

1. Outer Clutch Pack Carrier with Clutch Housing
2. Seals Quantity: 4
3. Inner Clutch Pack Carrier CAUTION: Risk of plates slipping. If the inner clutch pack carrier is raised or removed, plates can slip. The multi-plate clutch can no longer be adjusted correctly.
4. Outer Discs Quantity: 4
5. Inner Discs Quantity: 4
6. Thrust Washer
7. Locking Ring If the securing ring was removed in order to install the discs, it should be replaced with a new ring of the same thickness.
8. Locking Ring Determine thickness when installing multi-plate clutch «MULTI-PLATE CLUTCH, ADJUSTING (DETERMINE CIRCLIP THICKNESS)»(/audi/tt/8j-2006-2010/remont/automatic-trans/#clutch-direct-shift-automatic-transmission-02e-awd-roadster)
9. Drive Plate
10. Locking Ring Replace

MULTI-PLATE CLUTCH

Special tools and workshop equipment required

1. Guide Sleeve T10302
2. Retaining Bar T10303
3. Dial Gauge Holder VW 387

Note. Clean the T10302 before using, do not use any scratched sleeves.

Removing

1. Transmission, securing to engine and transmission holder, refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster__transmission-securing-in-enginetransmission-holder) .

Drain the transmission fluid. Refer to TRANSMISSION FLUID, REPLACING OR FILLING AFTER REPAIR .

Replace the transmission oil filter. Refer to TRANSMISSION FLUID FILTER .

Remove the ring -2- from the clutch end cover with a screwdriver -1- -arrow-.

Scheme 547

Remove the clutch end cover -2- through the opening for the starter using a screwdriver -1- or a pry bar -arrow-.

Scheme 548

Remove the locking ring -2- from the drive plate with a screwdriver -1- -arrow-.

Scheme 549

Remove the drive plate -arrows-.

Scheme 550

Remove the locking ring -arrow- using a screwdriver or needle nose pliers.

Scheme 551

Remove multi-plate clutch from the transmission.

Scheme 552

When the multi-plate clutch is removed, check whether clutch bell housing was damaged during removal.

Pull out the pump shaft -A- and lay it to the side.

Scheme 553

Installing

Scheme 554

Note. The drive plate circlip delivered in the replacement parts package will be installed later.

Remove the new drive plate circlip from packaging and lay it aside.

Remove the multi-plate clutch from packaging while securing drive plate.

Install the old drive plate locking ring -A- in the multiplate clutch removed earlier.

Scheme 555

1. Installed position: Drive plate tab and outer clutch pack carrier teeth marked in color must lie between ends of circlip.

Using a screwdriver, make sure the circlip is completely engaged.

On the bottom side of multi-plate clutch, check whether the hub sealing rings are seated correctly and engage them in one another if necessary.

Scheme 556

1. Installed position: Ends of rings offset to one another.

Position the T10303 on the clutch end plate seat as illustrated.

Scheme 557

Insert the multi-plate clutch in the clutch bell housing by turning and lifting and pressing drive plate into outer clutch pack carrier with both thumbs -arrows-.

Scheme 558

Note. Do not let the multi-plate clutch fall into the inner clutch pack carrier.

Have a second technician hold the T10303 as illustrated until clutch end plate is installed.

Scheme 559

Note. To prevent the T10303 from rotating in place, do not rotate multi-plate clutch.

Verify that the protruding tab -arrow- of the drive plate is positioned between the color-marked teeth of the outer clutch pack carrier.

Scheme 560

If there is no marking, mark the location of the drive plate to outer clutch pack carrier circumference for reinstallation with a waterproof marker as shown in the illustration.

Note. When installing, drive plate tab must be placed back on this marked location.

Remove the old locking ring -2- with a screwdriver -1- -arrow-.

Remove the drive plate -arrows-. If necessary, carefully pry the drive plate out of the outer clutch pack carrier teeth using a screwdriver.

Move the drive plate to the side.

Scheme 561

Find the 2 mm thick circlips in the replacement parts package.

Note. For the initial measurement, temporarily insert 2 mm thick circlip and then, after the measurement has been determined, replace it with the final circlip.

Insert a 2 mm locking ring -arrow-.

Attach VW 387 to transmission flange.

Scheme 562

For the 1st measurement, place dial gauge measuring tip on input shaft, as show in the illustration.

Set the dial gauge with 2 mm preload to "0".

Raise the multi-plate clutch all the way up.

Read the measurement (= input shaft axial play) and note.

For the 2nd measurement, place dial gauge measuring tip on inner clutch pack carrier hub, as show in the illustration.

Scheme 563

Note. Measuring tip must not be placed on circlip.

Set the dial gauge with 2 mm preload to "0".

Raise the multi-plate clutch all the way up.

Read the measurement and note.

The new circlip will be determined according to the following formula

Circlip = 2nd measurement - 1st measurement + 1.85 (= constant value)

The new circlips are staggered in 0.1 mm increments. Round to the closest number when selecting: Up to 0.049, round down, from 0.050, round up.

Example

1. Measurement determined for new circlip 2.27 mm, new circlip rounded up to 2.3 mm thick.
2. Measurement determined for new circlip 2.24 mm, new circlip rounded down to 2.2 mm thick.

Note. If the measurement determined for the new circlip is 2 mm, the circlip that was inserted temporarily remains installed.

Remove 2 mm thick circlip that was inserted temporarily for the measurement and replace with circlip thickness just determined.

Note. The circlips may be used only one time. Dispose of the removed circlip that was inserted temporarily as well as the remaining circlips.

Insert pump shaft by raising shaft and turning slightly -arrow- so it engages completely in splines.

Scheme 564

Insert drive plate in multi-plate clutch.

1. The protruding tab on the drive plate -arrow- must be installed between the marked teeth or the marking applied to the outer clutch pack carrier.

Install the new drive plate circlip.

Scheme 565

1. Installed position: The drive plate tab and marked teeth or outer clutch pack carrier marking that was applied must lie between the ends of the circlip.

Using a screwdriver, make sure the circlip is completely engaged.

Remove the T10303 between the multi-plate clutch and the housing.

Scheme 566

Clean clutch end cover outer seal contact surface.

Scheme 567

Remove the clutch end cover from the replacement parts package, only touching cover on outer edge.

Scheme 568

Clean the end of transmission shaft.

Note. Only the clutch end cover outer seal may be coated with gear oil. If there are stickers on the outside or inside of the clutch end cover, they must be removed without leaving any residue.

Place the T10302 on a level surface.

Scheme 569

To form the inner seal to the new clutch end cover, guide clutch end cover with outer side down evenly and horizontally over the T10302.

Remove the T10302 upward out of the clutch end cover.

Place the T10302 on the end of the multi-plate clutch shaft.

Scheme 570

Guide the clutch end cover with outer side up horizontally over the T10302 and press it evenly into the seat.

If necessary, carefully pry clutch end cover into seat with a screwdriver -arrow-, as illustrated until it is possible to install the shaft ring.

Scheme 571

Install clutch end cover shaft ring in transmission housing by counter holding shaft ring on the opposite side so it remains in its groove.

Using a screwdriver, make sure the shaft ring is completely engaged.

Fill the transmission fluid for the S-Tronic transmission after installing it. Refer to TRANSMISSION FLUID, REPLACING OR FILLING AFTER REPAIR .

Perform a basic setting using the vehicle diagnostic tester.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 572

Scheme 573

1. Guide Sleeve T10302
2. Retaining Bar T10303
3. Not illustrated
4. Dial Gauge Holder VW 387

See also:
• TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER
• TRANSMISSION FLUID, REPLACING OR FILLING AFTER REPAIR
• TRANSMISSION FLUID FILTER
• MULTI-PLATE CLUTCH
• MULTI-PLATE CLUTCH, ADJUSTING (DETERMINE CIRCLIP THICKNESS)