Volkswagen Workshop Service and Repair Manuals

Gearboxes up to 12.92

Note:

When performing repairs to the clutch, ensure that the ball valve (arrow) is not damaged.

• Supporting ring
• ◆ 4-piece, unclip from inner plate carrier
• ◆ Inserting =>Fig. 4
• Inner plate carrier
• ◆ Inserting =>Fig. 6
• ◆ Assembling =>Fig. 4
• Circlip
• ◆ Different thicknesses
• ◆ Mark after removing and insert in same position

• Thrust plate
• ◆ Smooth side faces inner plate
• ◆ Insert together with inner plate carrier => Fig. 4
• Inner plate
• ◆ Quantity=> Page 00-3
• ◆ Insert together with inner plate carrier => Fig. 4
• Outer plate
• ◆ Quantity=> Page 00-3
• ◆ Insert together with inner plate carrier => Fig. 4
• Thrust plate
• ◆ Curved side to diaphragm spring
• ◆ Installing=> Fig. 5
• Circlip
• ◆ Installing=> Fig. 3
• Diaphragm spring
• ◆ Insert with curved side to piston

• Circlip
• ◆ Removing and installing =>Fig. 2
• Intermediate spring ring
• ◆ With spring supporting shell and compression springs
• Operating ring
• ◆ Insert with rounded surface facing intermediate spring ring
• Disc spring
• ◆ Curved side faces operating ring
• ◆ Installation position =>Fig.1
• Disc spring
• ◆ Curved side faces operating ring
• ◆ Installation position =>Fig.1

• Piston
• ◆ Sealing lips are vulcanised to piston
• ◆ Moisten sealing lips with ATF before installing
• ◆ Turn piston slightly when installing
• Piston ring (small ø)
• ◆ Check that it is correctly located
  => Fig. 7
• ◆ Fitting => Fig. 8
• Piston ring
• ◆ Check that it is correctly located
  => Fig. 7
• ◆ Fitting => Fig. 8
• Clutch housing with turbine shaft
• ◆ Check bearing bushes. Replace housing if bushes are damaged.
• ◆ Before inserting the inner plate carrier insert diaphragm spring (item 9), circlip (item 3) and one inner and outer plate in the clutch housing =>Fig. 5

• Piston ring
• ◆ Check that it is correctly located
  => Fig. 7
• ◆ Fitting => Fig. 8
• Piston ring
• ◆ Check that it is correctly located
  => Fig. 7
• ◆ Fitting => Fig. 8
• Piston ring
• ◆ Check that it is correctly located
  => Fig. 7
• ◆ Fitting => Fig. 8
• Piston ring
• ◆ Check that it is correctly located
  => Fig. 7
• ◆ Fitting => Fig. 8

→ Fig.1    Installation position of disc springs

• ‒ Install disc springs -1- and -2- so that when placed together the outer edges touch. There is a clearance at the inner diameter.

→ Fig.2    Removing and installing circlip

• ‒ Press intermediate spring ring down far enough for the circlip (arrow) to be inserted in the groove.

→ Fig.3    Inserting circlip

• ‒ Insert circlip (arrow) in the groove, diaphragm spring is slightly pretensioned.

→ Fig.4    Placing inner and outer plates on inner plate carrier and clipping in support ring

• ‒ Insert the thrust plate and the inner and outer plates and then clip supporting ring (arrow) in place.

Note:

An inner and an outer plate must be placed in the clutch housing before inserting the inner plate carrier.

→ Fig.5    Inserting pressure plate, first inner and first outer plate into clutch housing

→ Fig.6    Inserting inner plate carrier and installing circlip (arrow)

• ‒ Lift inner plate carrier slightly to install circlip.

→ Fig.7    Checking seating of piston rings

There are two piston rings installed on the turbine shaft inside the clutch housing.

• ‒ Ensure that the ends of the piston rings are hooked together.

→ Fig.8    Fitting and hooking ends of piston ring together

• ‒ Place piston ring in groove.
• ‒ To hook ends together press sides of ring in and guide ends over one another.
• ‒ Do not twist piston ring out of groove on one side.