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LUK生产7速干式双离合变速箱修理手册

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LUK生产7速干式双离合变速箱修理手册

LUKREPAIRSOLUTIONFORDRYDOUBLECLUTCHESTECHNOLOGY/FAILUREDIAGNOSISSPECIALTOOL/REMOVALANDINSTALLATIONGUIDELINES7SPEEDTRANSMISSIONOAMINAUDI,SEAT,SKODAANDVOLKSWAGEN2COPYRIGHTSCHAEFFLERAUTOMOTIVEAFTERMARKETGMBHTORQUEISTRANSMITTEDTOTHEGEARBOXBYTHESOLIDSHAFTTHESECOND,FOURTH,SIXTHANDREVERSEGEARSAREENGAGEDUSINGCLUTCHK2TORQUEISTRANSMITTEDTOTHEGEARBOXBYTHEHOLLOWSHAFTEACHGEARSETOFTHE7SPEEDDOUBLECLUTCHGEARBOXFUNCTIONSSIMILARLYTOAMANUALGEARBOXEACHGEARSETISASSIGNEDONECLUTCHBOTHCLUTCHESAREPOSITIONEDONTWONESTEDGEARBOXINPUTSHAFTS,THEOUTERHOLLOWSHAFTANDTHEINNERSOLIDSHAFTOPERATINGPRINCIPLE21DOUBLECLUTCH462R1357462R135781DRIVERINGWITHPRESSUREPLATEFORK12CLUTCHDISCK13CENTRALPLATE4CLUTCHDISCK25PRESSUREPLATEK26LEVERSPRINGWITHSELFADJUSTINGDEVICEFORK27CLUTCHCOVERWITHSELFADJUSTINGDEVICEFORK18LEVERSPRINGK19RETAININGRING10STOPRING32145678910WITHONEOFTHECLUTCHESENGAGED,TORQUEISTRANSFERREDVIATHECLUTCHDISCTOTHECORRESPONDINGGEARBOXINPUTSHAFTTHECENTRALPLATEISTHECORECOMPONENTOFTHECLUTCHITISMOUNTEDONTHEHOLLOWSHAFTBYMEANSOFASUPPORTBEARINGITISCONNECTEDTOTHEDMF,ANDCONSEQUENTLYTOTHEENGINEBYMEANSOFTHEDRIVECOVERANDSPLINE1CRANKSHAFT2DMF3CENTRALPLATE4SUPPORTBEARING5PRESSUREPLATEK16CLUTCHDISCK17PRESSUREPLATEK28CLUTCHDISCK29ENGAGEMENTBEARINGK210ENGAGEMENTBEARINGK111GEARBOXINPUTSHAFT1SOLIDSHAFT12GEARBOXINPUTSHAFT2HOLLOWSHAFT13RETAININGRING14DIAPHRAGMSPRINGK215DIAPHRAGMSPRINGK113141091578352461112121DOUBLECLUTCHDESIGN2DESIGNANDOPERATINGPRINCIPLEOFTHEDRYDOUBLECLUTCHSYSTEM9TODRIVEINSECOND,FOURTH,SIXTHORREVERSEGEARTHELARGEENGAGEMENTLEVERISPULLEDBACK,WHICHDISENGAGESCLUTCHK1SIMULTANEOUSLYTHEMECHATRONICSYSTEMACTUATESTHESMALLENGAGEMENTLEVERCLUTCHK2ENGAGESANDALLOWSTORQUETOBETRANSFERREDTOTHEHOLLOWSHAFTTODRIVEINFIRST,THIRD,FIFTHORSEVENTHGEAR,THEMECHATRONICSYSTEMACTUATESTHELARGEENGAGEMENTLEVERCLUTCHK1ISENGAGEDANDPOWERISTRANSMITTEDTOTHESOLIDSHAFTWHENDRIVINGINAN“ODD”GEAR,THEMECHATRONICUNITSELECTSTHENEXTHIGHERORLOWERGEARANDWAITSFORCLUTCHK2TOENGAGEFUNCTIONTHEPUSHINGMOTIONOFTHELARGEENGAGEMENTLEVERISTRANSFORMEDINTOPULLINGMOTIONBYMEANSOFPIVOTPOINTSPRESSUREPLATE1ISPULLEDTOWARDSTHECENTRALPLATETOENGAGECLUTCHK1TOENGAGECLUTCHK2THESMALLENGAGEMENTLEVERPUSHESPRESSUREPLATE2AGAINSTCLUTCHK210THEFLYWHEELUSEDONTHEDCTISASPECIALVERSIONOFTHELUKDUALMASSFLYWHEELSIMILARLYTOTHEDMFUSEDINCONVENTIONALMANUALTRANSMISSIONSITSMASSISSPLITINTOAPRIMARYANDSECONDARYMASSCONTRARYTOACONVENTIONALDMF,HOWEVER,THESECONDARYMASSOFTHESPECIALVERSIONISNOTDESIGNEDASANINTEGRALFLYWHEELMASSBUTASAFLANGEITSONLYPURPOSEISTOCONNECTTHEPRIMARYMASSTOTHEDOUBLECLUTCHTHEFUNCTIONNORMALLYPERFORMEDBYTHESECONDARYMASSISTAKENONBYTHEDOUBLECLUTCHMOUNTEDONTHEHOLLOWSHAFTTHISELIMINATESTHENEEDFORDIRECTSUPPORTOFBOTHMASSES,WHICHISUSUALLYREALISEDBYMEANSOFBALLBEARINGSORPLAINBEARINGSONCONVENTIONALDMFDESIGNSUNLIKEACONVENTIONALDMFTHESECONDARYMASSOFTHESPECIALVERSIONLACKSAFRICTIONSURFACEWHICHISALSOINTEGRATEDINTHEDOUBLECLUTCHTHECENTRALPLATEPROVIDESTHEFRICTIONSURFACESFORBOTHCLUTCHESTHEDMFFRICTIONSURFACEWASSUBSTITUTEDWITHAFLANGEWITHINNERTEETHWHICHENGAGESWITHTHEDRIVERINGGEAROFTHEDOUBLECLUTCHTOPREVENTNOISEFROMTOOTHBACKLASHBETWEENTHETOOTHEDRINGSACLAMPRINGISUSEDWHICHGENERATESSUFFICIENTPRELOADOFTHETOOTHEDRINGSTOPREVENTFLANKCLEARANCE22DUALMASSFLYWHEELFUNCTIONINGPRINCIPLEOFTHEDMFENGINETORQUEISAPPLIEDTOTHEDMF’SPRIMARYMASSTHEINTERNALDAMPINGSYSTEMABSORBSROTATIONALIRREGULARITIESANDTORQUEISPASSEDONTOTHECLUTCHVIATHESECONDARYMASSNOTEMOREDETAILEDINFORMATIONONTHEDMFANDITSOPERATINGPRINCIPLECANBEFOUNDINTHELUK“DUALMASSFLYWHEEL”BROCHURE31PRIMARYMASSWITHARCSPRINGS2FLANGEWITHINTERNALTOOTHINGTOENGAGEWITHDCDRIVERINGGEAR3CLAMPRING4PRIMARYMASSCLOSINGPLATEWITHSTARTERRINGGEAR2142DESIGNANDOPERATINGPRINCIPLEOFTHEDRYDOUBLECLUTCHSYSTEM1123ENGAGEMENTSYSTEMONAMANUALTRANSMISSIONWITHSINGLEDISCCLUTCH,THECLUTCHISENGAGEDINTHEIDLESTATEPRESSINGTHECLUTCHPEDALDISENGAGESTHECLUTCHANDINTERRUPTSPOWERTRANSMISSIONTHISISTHEFUNCTIONOFTHERELEASESYSTEMINCONTRAST,THECLUTCHESOFADCTAREDISENGAGEDINTHEIDLESTATEACTUATINGTHEENGAGEMENTLEVERSENGAGESTHECLUTCHESTHISISWHYTHESYSTEMISCALLEDTHEENGAGEMENTSYSTEMTHEENGAGEMENTSYSTEMCOMPRISESTWOENGAGEMENTLEVERS2AND5OPERATINGINDEPENDENTLYOFEACHOTHERANDTWOENGAGEMENTBEARINGS3AND7ONETOACTUATEEACHOFTHECLUTCHESTHEENGAGEMENTLEVERSARELOCKEDINPOSITIONBYTWOGUIDESLEEVESTHEADJUSTINGSHIMS4AND6AREPOSITIONEDABOVEORBENEATHTHEENGAGEMENTBEARINGTHEIRTASKISTOCOMPENSATEFORAXIALTOLERANCESOFADJACENTCOMPONENTSFUNCTIONINGPRINCIPLEOFTHEENGAGEMENTSYSTEMBYMEANSOFTWOPUSHRODSTHEMECHATRONICSYSTEMALTERNATELYACTUATESTHEENGAGEMENTLEVERSANDCORRESPONDINGENGAGEMENTBEARINGSDURINGOPERATIONTHEENGAGEMENTLEVERSARESUPPORTEDBYTHECOUNTERBEARING,THEREBYPUSHINGEACHENGAGEMENTBEARINGTOWARDSTHECORRESPONDINGDIAPHRAGMSPRINGTHERESPECTIVECLUTCHISENGAGEDANINTEGRATEDSELFADJUSTINGMECHANISMCOMPENSATESFORCLUTCHDISCWEARTHISWAY,PUSHRODTRAVELISKEPTCONSTANTTHROUGHOUTTHEIRENTIRESERVICELIVES1GUIDESLEEVEFORK1ENGAGEMENTBEARING2LARGEENGAGEMENTLEVER3ENGAGEMENTBEARINGFORK112345674ADJUSTINGSHIMCLUTCHK15SMALLENGAGEMENTLEVERWITHGUIDESLEEVEFORK26ADJUSTINGSHIMCLUTCHK27ENGAGEMENTBEARINGFORCLUTCHK2123TROUBLESHOOTINGDOUBLECLUTCHFAILURE3TROUBLESHOOTINGDOUBLECLUTCHFAILUREBEFOREPROCEEDINGTOANYREPAIRWORKONTHEDOUBLECLUTCH,ASKYOURCUSTOMERSOMEBASICQUESTIONSTOPINPOINTPOSSIBLECAUSESOFDAMAGEIFTHECARISROADWORTHY,CARRYOUTATESTDRIVETOGETHERWITHYOURCUSTOMERTHECUSTOMERSHOULDBEBEHINDTHEWHEELANDPOINTINGOUTPROBLEMSOCCURRINGDURINGOPERATIONASKYOURCUSTOMERSOMETARGETEDQUESTIONSWHATEXACTLYDOESNOTWORK,WHATEXACTLYISTHECUSTOMER’SCOMPLAINTWHENDIDTHEPROBLEMFIRSTOCCURDIDTHEPROBLEMMANIFESTITSELFSUDDENLYORGRADUALLYWHENDOESTHEPROBLEMOCCURGFROMTIMETOTIME,OFTEN,ALWAYSUNDERWHICHOPERATINGCONDITIONSDOESTHEPROBLEMOCCURGEGWHILEDRIVINGOFF,ACCELERATING,DECELERATING,WHENTHEVEHICLEISCOLDORATOPERATINGTEMPERATUREWHATISTHEMILEAGEOFTHECARARETHEREEXTRAORDINARYLOADCONDITIONSUNDERWHICHTHEVEHICLEOPERATESGEGTOWING,OVERLOADING,TAXI,FREQUENTUPHILLDRIVING,FLEETVEHICLE,RENTALCAR,DRIVINGSCHOOLWHATISTHEDRIVINGPROFILEGCITYTRAFFIC,SHORTDISTANCE/OVERLAND,LONGDISTANCEHAVETHEREBEENPREVIOUSTRANSMISSION/CLUTCHREPAIRSGIFYES,ATWHATMILEAGE,FORWHATREASON,WHATREPAIRSWERECARRIEDOUTGENERALVEHICLEINSPECTIONCHECKTHEFOLLOWINGPRIORTOSTARTINGREPAIRFAULTCODESSTOREDINTHECONTROLUNITENGINE,GEARBOX,CLUTCH,COMFORT,CANBUSBATTERYPOWERPROFESSIONALHANDLINGOFTHEDMFANDDOUBLECLUTCHTHEFOLLOWINGINSTRUCTIONSPROVIDEIMPORTANTINFORMATIONONTHECORRECTHANDLINGOFTHEDMFANDDOUBLECLUTCHDONOTINSTALLADMFAND/ORDOUBLECLUTCHWHICHHASBEENDROPPEDDONOTCLEANTHECOMPONENTSINAPARTSWASHINGMACHINEDONOTDISASSEMBLETHECOMPONENTS31GENERALREPAIRGUIDELINESDOUBLECLUTCH,ENGINESIDEDOUBLECLUTCH,GEARBOXSIDE13BEFOREREMOVINGTHEGEARBOXANDCLUTCH,PERFORMASYSTEMCHECKUSINGANAPPROPRIATEDIAGNOSTICTESTERIFNODEFECTCANBEIDENTIFIEDANDOTHERCAUSESCANDEFINITELYBERULEDOUT,DISENGAGEMENTPROBLEMSANDCLUTCHSLIPMAYRESULTAMONGOTHERTHINGSFROMINCORRECTENDFLOATATCLUTCHESK1ANDK2IFTHEPROBLEMSMANIFESTTHEMSELVESIMMEDIATELYAFTERTHECLUTCHWASREPLACED,THEENGAGEMENTSYSTEMMAYHAVEBEENSETINCORRECTLYREFERTOPAGE26ONWARDANDTHEPROCEDUREMUSTBEREPEATED36DIAGNOSISTHEGEARBOXANDCLUTCHELECTRONICSMECHATRONICSAREDIAGNOSABLETHESYSTEMCANBEREADUSINGSUITABLEDIAGNOSTICEQUIPMENTSYSTEMADJUSTMENTS,WHICHAREREQUIREDAFTEREVERYCLUTCHREPAIR,CANALSOBECONFIGUREDTHISWAYAWEARTESTCANBEPERFORMEDINADDITIONTOAGENERALFUNCTIONTESTOFTHEDOUBLECLUTCHTODOSO,ADHERETOTHEFOLLOWINGPROCEDURE1ENSUREENGINEISATOPERATINGTEMPERATURE2TESTDRIVECARINMANUALSHIFTMODE3WHENINSIXTHGEARMAINTAINENGINESPEEDBETWEEN1,000AND1,500RPM4THENGIVEFULLACCELERATIONCAUTIONDONOTACTIVATEKICKDOWN5OBSERVETACHOMETER6IFSPEEDVARIESBYUPTO200RPMUNDERACCELERATION,DOUBLECLUTCHWEARLIMITHASBEENEXCEEDED7IFSPEEDREMAINSCONSTANT,DOUBLECLUTCHHASNOTYETREACHEDWEARLIMIT8REPEATTESTSTEPS37WHILEINSEVENTHGEAR33VISUALINSPECTIONASARULE,ALWAYSCHECKTHECLUTCHSYSTEMENVIRONMENTFORLEAKAGEANDDEFECTSBEFORECARRYINGOUTCLUTCHREPAIRWORKBEFOREREPLACINGTHECLUTCHMERELYONSUSPICIONOFMALFUNCTION,REMEDYANYDAMAGECAUSEDBYBROKENOFFPARTSOROILLEAKAGEDUETODEFECTIVESEALSORSEALRINGSREPLACECLUTCHIFCONTAMINATEDWITHOIL34NOISETOINVESTIGATECOMPLAINTSOFNOISECOMINGFROMTHEDOUBLECLUTCHENVIRONMENTITISESSENTIALTODETERMINEDURINGTHETESTDRIVEWHETHERNOISEISCAUSEDBYADJACENTCOMPONENTS,EGTHEEXHAUSTSYSTEM,HEATSHIELDS,ENGINEMOUNTS,FRONTENDACCESSORIESETCTOPINPOINTTHENOISESOURCETURNOFFTHERADIO,AIRCONDITIONINGANDVENTILATIONSYSTEMSYOUMAYALSOUSEASTETHOSCOPEATTHEGARAGE32WEARTEST35DISENGAGEMENTPROBLEMSANDCLUTCHSLIP31GENERALREPAIRGUIDELINES

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