Volkswagen Workshop Service and Repair Manuals

1st to 3rd gear clutch -K1-: disassemble and assemble Check if the clutch works → Fig.

1 -	Sealing ring

q	Remove making a lever with a screwdriver

2 -	Pressure disc

q	Assemble → Fig.

q	Determine the thickness → Fig.

3 -	Internal disc

q	Assemble → Fig.

q	Quantity → Chapter

4 -	External disc

q	Assemble → Fig.

q	Quantity → Chapter

5 -	Dish spring

q	Assemble → Fig.

6 -	Sealing ring

q	Disassemble and assemble = → Fig.

7 -

Retainer

q	Always replace

8 -	Plunger cover

q	Before placing it, apply ATF on the retainers

9 -

Spring

q	Place it between the plunger and the plunger cover

10 -

Retainer

q	Always replace

q	The sealing lip must be facing the clutch bellhousing

11 -

Retainer

q	Always replace

12 -

Plunger

q	Allocate the spare due to the distinctive letters in the transmission

q	Assemble → Fig.

13 -	Clutch bellhousing with turbine shaft

14 -

Segment

q	Check if it is properly seated

q	Do not over-expand

Fig.1 - Disassemble and assemble the sealing ring –  Push the plunger cover with the spring downward until it is possible to keep the sealing ring in the notch -arrow-.

Fig.2 - Assemble the external and internal discs The convex side of the dish spring (with small diameter) must be facing the clutch bellhousing. –  Place the external discs -2- and the internal discs -4- over the dish spring -3-. –  Place the bearing disc -5- over the last internal disc. –  Put the sealing ring -1- in the clutch bellhousing notch.

Fig.3 - Determine the bearing disc thickness. –  With a gauge "A", measure the oscillation between the bearing disc and the sealing ring.

Component	Gap	Wearing limit
Clutch K1	0,45 ... 0.85 mm	1.05 mm

–  If the wearing limit is reached with the clutch used, the discs must be changed and a new, proper bearing disc must be selected. –  Allocate the discs and the bearing disc due to the distinctive letters in the transmission.

Fig.4 - Check if the clutch works –  Before assembling the plunger, apply ATF over the sealing lips and the retainers. –  Slightly turn the plunger when assembling it –  Once the plunger is assembled in the clutches or the brakes, it must be able to be manually turned easily in both directions -arrows-. –  If not, the sealing lips or the retainers may not be completely inserted or are damaged. –  Disassemble the plunger if such abnormality occurs. –  Check if the sealing lips or the retainers are damaged and change them if necessary –  Assemble the plunger and review it again.

–  Blow compressed air into the pressure channel -arrow-. –  Plug the hole in the opposite side. –  The clutch plunger must compress the disc pack. –  Let compressed air bleed. The disc pack must return to its resting position