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Disassembling and assembling K2 the reverse gear-clutch > < Disassembling and assembling free wheel with B1 piston.

Octavia Mk1

Disassembling and assembling through 1st and 3rd gear clutch K1
Disassembling and assembling through 1st and 3rd gear clutch -K1-
Special tools and workshop equipment required
t  Pressure plate -MP3-406 (VW 401)-
t  Pressure plate -MP3-407 (VW 402)-
t  Thrust piece -MP3-408 (VW 412)-
t  Pipe section -MP3-486 (40 - 203/1)-
t  Pressure plate -MP6-418 (VW 442)-
   
  Note
t  The clutch must only be disassembled for cleaning and for carrying out a visual inspection.
t  On certain gearboxes, the clutches -K1- and -K3- can be pressed together.
t  press off -K1- from -K3- → Chapter.
t  press -K1- onto -K3- → Chapter.
1 - Top mount
q   4-part, unclip from inner plate support
q   inserting → Fig.
2 - Inner plate support
q   inserting → Fig.
q   assembling → Fig.
3 - Circlip
q   Differing thickness
q   mark after removing and install again in same position
q   do not interchange with circlips of other clutches
4 - Pressure plate
q   smooth side to the inner plate
q   insert together with the inner plate support → Fig.
5 - Inner plate
q   Piece number → Chapter
q   installing → Fig.
q   place new inner plate into ATF for 15 minutes before installing
6 - Outer plate
q   Piece number → Chapter
q   installing → Fig.
q   always 1.5 mm thick
7 - Outer plate
q   always 2.0 mm thick
q   installing → Fig.
8 - Wave spring washer
9 - Circlip
q   removing and installing → Fig.
q   mark after removing and install again in same position
q   do not interchange with circlips of other clutches
10 - Piston cap
q   The sealing lips are vulcanized to the cover
q   moisten sealing lips with ATF before inserting
q   turn piston cap slightly when installing
11 - Spring spacer ring
q   with spring support panel and pressure springs
12 - Piston
q   for removal, lift off from the clutch bell at several points using a screwdriver
q   The sealing lips are vulcanized to the pistons
q   moisten sealing lips with ATF before inserting
q   turn piston slightly when installing
13 - Clutch bell
q   before installing the inner plate support of the wave spring washer Pos. 8, place the inner and outer plates in the clutch bell → Fig.

   
Removing and installing circlip
–  Press the piston cap with spring spacer ring down until the circlip -arrow- can be removed and installed.
  S38-0012
Place the pressure plate and plates on the inner plate support
–  Position pressure plate -a- with the smooth side to the inner plate and with the offset side towards the inner plate support.
–  Fit on 3 inner plates -b- and 2 outer plates -c- (1.5 mm).
–  Clip on top mount with edge -arrows-.
  Note
t  Correctly lock the retaining lugs.
t  Insert wave spring washer and further plates into the clutch bell → Fig..
  N38-0003
Insert wave spring washer and outer and inner plates into the clutch bell
–  First insert the wave spring washer.
–  Insert 2 mm thick outer plate.
–  Insert the remaining inner and outer plates.
  N38-0042
Insert inner plate support and install circlip
–  To install the circlip -black arrow- raise inner plate support slightly -white arrows-.
  N38-0043

Disassembling and assembling K2 the reverse gear-clutch > < Disassembling and assembling free wheel with B1 piston.