Volkswagen Workshop Service and Repair Manuals

Gearboxes from 01.93

• Supporting ring
• ◆ 4-piece, unclip from inner plate carrier
• ◆ Inserting =>Fig. 2
• Inner plate carrier
• ◆ Inserting =>Fig.4
• ◆ Assembling =>Fig.2
• 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.2

• Inner plate
• ◆ Quantity=> Page 00-3
• ◆ Installing=> Fig.2
• Outer plate
• ◆ Quantity=> Page 00-3
• ◆ Installing=> Fig.2
• ◆ Always 1.5 mm thick
• Outer plate
• ◆ Always 2 mm thick
• ◆ Installing=> Fig.2
• Corrugated washer
• Circlip
• ◆ Removing and installing =>Fig.1
• Piston cap
• ◆ Sealing lips are vulcanised to cap
• ◆ Moisten sealing lips with ATF before installing
• ◆ Turn cap slightly when installing

• Intermediate spring ring
• ◆ With spring supporting shell and compression springs
• 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. 5
• ◆ Fitting => Fig. 6
• Piston ring
• ◆ Check that it is correctly located
  => Fig. 5
• ◆ Fitting => Fig. 6

• Clutch housing with turbine shaft
• ◆ Check bearing bushes. Replace housing if bushes are damaged.
• ◆ Before inserting the inner plate carrier corrugated washer (item 8), insert inner and outer plates in the clutch =>Fig.3
• Piston ring
• ◆ Check that it is correctly located
  => Fig. 5
• ◆ Fitting => Fig. 6

→ Fig.1    Removing and installing circlip

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

→ Fig.2    Fitting thrust plate and plates onto inner plate carrier

• ‒ Install thrust plate -a- with smooth side facing inner plate and stepped side towards inner plate carrier.
• ‒ Install 3 inner plates -b- and 2 outer plates -c-.
• ‒ Insert supporting ring with step (arrow) after installing thrust plate as well as inner and outer plates.

Notes:

• ◆ Locate locating lugs correctly.
• ◆ Installing corrugated washer and further plates in clutch housing => Fig. 3.

→ Fig.3    Installing corrugated washer and inner and outer plates in clutch housing

• ‒ First insert corrugated washer.
• ‒ Insert 2 mm thick outer plate.
• ‒ Insert remaining inner and outer plates.

→ Fig.4    Inserting inner plate carrier and installing circlip (arrow).

• ‒ Lift inner plate carrier slightly to install circlip.

→ Fig.5    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.6    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.