Date:         Tue, 4 Jul 2006 17:51:06 +1000
Reply-To:     David Yates <dyates1@BIGPOND.NET.AU>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         David Yates <dyates1@BIGPOND.NET.AU>
Subject:      Help rebuilding Auto Transmission - Forward clutch assembly
Content-Type: text/plain; charset="us-ascii"

It's a long shot, I know, but I hope someone on the list can help!



I'm rebuilding my '86 010 series Transporter Auto transmission.   I have the
transmission sitting on the bench with the opening upwards.



The Bentley manual (38.17) indicates that when assembling the Forward
clutch, the thrust plate goes in and then ONE of the inner-splined clutch
plates goes in before the Forward planetary ring gear.  (This has teeth (a
"ridge") on its outside that prevent the inner splined plates from passing
them.) Then the other plates go in before the pressure plate and circlip.
Fine, BUT. . . when I do this, the Forward planetary gear set (38.7) seems
to sit too high.  The teeth on the three gears sit proud of the inner
planetary ring gear teach by 1-2mm.  The picture I took as I disassembled
implies the gear teeth were not above (proud of) the ring gear, but flush
with them or even a little lower.



I THINK I can achieve this level IF I put two of the inner splined plates
below the protruding teeth (ridge) on the outside of forward planetary ring
gear, but this is contrary to the manual.  ONE of the parts lists I found on
the web somewhere does actually show two (rather than 1) of these plates
below the protruding teeth, but I am certain I only had one there when I
pulled the beast apart.



Has anyone faced this issue?  Does anyone have an idea of which way I should
go, or are the gear teeth and the inner planetary ring gear not flush??  I
cannot work out where the problem may be.



The Chilton's guide I have (p2-48) shows the same arrangement as the Bentley
manual, though the figure is sourced to VW America.



ANY help greatly appreciated



Dave Yates,

downunder