Clutch - Direct Shift Automatic Transmission 02e (fwd) (coupe) Audi TT 8J

MULTI-PLATE CLUTCH ASSEMBLY OVERVIEW

1. The clutch of Direct Shift transmission 02E contains 2 clutch packs and is therefore named multi-plate clutch. The outer, larger clutch pack is designated K 1 (clutch 1) and shifts reverse gear, as well as gears 1, 3 and 5. The inner, smaller K 2 (clutch 2) shifts 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 shift function and shorten service life.

Replacement Part Package

Scheme 246

1. Multi-Plate Clutch With circlip CAUTION: Risk of discs in multi-plate clutch slipping. The multi-plate clutch must not be disassembled at this time. If the drive plate (upper part of multi-plate clutch) comes out of the outer clutch pack carrier teeth, the plates can slip. Then, 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-fwd-coupe__multi-plate-clutch)
2. Circlips Qty. 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-fwd-coupe)
3. Clutch End Cover
4. Shaft Ring

Individual Parts of Disassembled Multi-Plate Clutch

Scheme 247

1. Outer Clutch Pack Carrier with Clutch Housing
2. Seals Qty. 4
3. Inner Lamella Carrier CAUTION: Risk of plates slipping. If the inner clutch pack carrier is raised or removed, plates can slip. Then, the multi-plate clutch can no longer be adjusted correctly.
4. Outer Clutch Discs Qty. 4
5. Inner Clutch Discs Qty. 4
6. Thrust Washer
7. Circlip In case circlip has been removed to insert new clutch discs, use a new circlip of the same thickness
8. Circlip 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-fwd-coupe)
9. Drive Plate
10. Circlip Replace

MULTI-PLATE CLUTCH

Special tools and workshop equipment required

1. Assembly sleeve T10302
2. Retaining Bar T10303

Note. Clean assembly sleeve T10302 before using, and do not use any scratched sleeves.

Removing

Proceed as follows

Drain transmission fluid. Refer to TRANSMISSION FLUID, CHANGING AND FILLING .

Remove Direct Shift transmission. Refer to TRANSMISSION, REMOVING .

Secure Direct Shift transmission vertically on assembly bracket. Refer to TRANSMISSION, SECURING ON ASSEMBLY STAND .

Replace transmission oil filter. Refer to TRANSMISSION OIL FILTER .

Pry out clutch end cover shaft ring -2- using a screwdriver -1- and remove -arrow-.

Scheme 248

Pry out -arrow- clutch end cover -2- through starter installation opening using a screwdriver -1- or assembly lever and remove.

Scheme 249

Pry out -arrow- drive plate circlip -2- with a screw driver -1-.

Scheme 250

Remove drive plate -arrows-.

Scheme 251

Pry out circlip -arrow- using screwdriver or needle nose pliers.

Scheme 252

Remove multi-plate clutch from transmission.

Scheme 253

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

Remove pump shaft -A- and lay aside.

Scheme 254

Installing

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

Remove new drive plate circlip from packaging and lay aside.

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

Scheme 255

Next, install old drive plate circlip -A- from removed multi-plate clutch.

Scheme 256

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

Using screwdriver, check whether circlip is completely engaged.

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

Scheme 257

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

Position Retaining Bar T10303 on clutch end plate seat as shown in illustration.

Scheme 258

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

Scheme 259

Note. Multi-plate clutch must not fall into inner clutch pack carrier.

Have a second technician hold Retaining Bar T10303 as shown in illustration until clutch end plate is installed.

Scheme 260

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

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

Scheme 261

If there is no marking, mark location of 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.

Pry out old circlip -2- with a screwdriver -1- -arrow-.

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

Lay aside drive plate.

Scheme 262

Find 2 mm thick circlips in 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 2 mm thick circlip -arrow-.

Attach Dial Gauge Holder VW 387 to transmission flange.

Scheme 263

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

Set dial gauge to 0 with 2 mm pre-load.

Raise multi-plate clutch up as far as stop.

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

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

Scheme 264

Note. Measuring tip must not be placed on circlip.

Set dial gauge to 0 with 2 mm pre-load.

Raise multi-plate clutch up as far as stop.

Read measurement and note.

The new circlip is determined by the following formula

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

The new circlips are staggered in 0.1 mm increments. Round to 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. Circlips must only be used one time. Dispose of 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 265

Insert drive plate in multi-plate clutch.

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

Install new drive plate circlip.

Scheme 266

1. Installation 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 screwdriver, check whether circlip is completely engaged.

Remove Retaining Bar T10303 between multi-plate clutch and housing.

Inner seal

Scheme 267

Clean clutch end cover outer seal contact surface.

Do not touch

Scheme 268

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

Scheme 269

Clean end of transmission shaft.

Note. Only 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 Guide Sleeve T10302 on level surface.

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

Scheme 270

Remove Guide Sleeve T10302 upward out of clutch end cover.

Place Guide Sleeve T10302 on end of multi-plate clutch shaft.

Scheme 271

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

If necessary, carefully pry clutch end cover into seat with a screwdriver -arrow-, as shown in illustration, until shaft ring can be installed.

Scheme 272

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

Using screwdriver, check whether shaft ring is completely engaged.

Install transmission. Refer to TRANSMISSION, INSTALLING .

Fill DSG gear oil. Refer to TRANSMISSION FLUID, CHANGING AND FILLING .

Connect Vehicle Diagnosis, Testing, and Information System VAS 5051B.

Perform basic setting

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 273

Scheme 274

1. Assembly sleeve T10302
2. Retaining Bar T10303

See also:
• TRANSMISSION FLUID, CHANGING AND FILLING
• TRANSMISSION, REMOVING
• TRANSMISSION, SECURING ON ASSEMBLY STAND
• TRANSMISSION OIL FILTER
• TRANSMISSION, INSTALLING
• MULTI-PLATE CLUTCH
• Multi-plate clutch, adjusting (determine circlip thickness)