Volkswagen Workshop Service and Repair Manuals

Functional check of clutch

=>Fig.4

• Circlip
• ◆ Mark after removing and insert in same position
• Thrust plate
• ◆ Installing => Fig.2
• ◆ Determining thickness => Fig.3
• Inner plate
• ◆ Installing => Fig.2
• ◆ Quantity
• Outer plate
• ◆ Installing => Fig.2
• ◆ Quantity=> Page 00-4
• Circlip
• ◆ Lever out with screwdriver
• ◆ Installing => Fig.1

• Spring supporting plate
• ◆ With springs
• ◆ Installing => Fig.1
• Oil seal
• ◆ Always renew
• Piston
• ◆ Spare part is allocated according to gearbox code letters
• ◆ Installing => Page 38-13
• Oil seal
• ◆ Always renew
• ◆ Sealing lip faces to clutch housing
• Clutch housing

→ Fig.1     Removing and installing circlip

• ‒ Place spring supporting plate on the piston of the -K2- clutch.
• ‒ Place circlip on spring supporting plate.
• ‒ Carefully press down circlip with spring supporting plate using press piece T 10002 until the circlip audibly locates in the groove.

→ Fig.2     Installing outer and inner plates

The sealing lip of sealing ring faces to clutch housing.

• ‒ Install outer plates -3- and inner plates -4- in clutch housing.
• ‒ Place pressure plate -2- on the last inner plate.
• ‒ Fit circlip -1- in the groove in the clutch housing.

→ Fig.3     Determining thickness for the pressure plate.

• ‒ Measure play between pressure plate and circlip using a feeler gauge "A".

• ‒ If the wear limit is reached on a used clutch, the plates must be replaced and the thickness for a new pressure plate must be calculated.
• ‒ Allocate plates and pressure plate according to gearbox code letters.

→ Fig.4     Functional check of clutch

• ‒ Before installing the piston moisten the sealing lips and sealing rings with ATF.

Sealing lip faces to clutch housing.

• ‒ Turn piston slightly when installing.
• ‒ It must be possible to turn the piston by hand in both directions (arrows) after it has been installed into clutches or brakes.

• ◆ If this is not the case, the sealing lips or sealing rings may catch or become damaged.

• ‒ If this defect occurs, remove piston again.
• ‒ Check sealing lips or sealing rings for damage, renew if necessary.
• ‒ Install piston again and check.

• ‒ Place shim between -K2- clutch and ATF pump.
• ‒ Place clutch -K2- on ATF pump and press downwards.
• ‒ → Blow compressed air into the pressure channel -arrow-.
• ‒ The clutch piston must press the plates together.
• ‒ Allow compressed air to escape. The set of plates must return to its rest position.