SEAT Workshop Service and Repair Manuals

Dismantling and assembling 1st to 3rd gear clutch -K1-

Special tools and workshop equipment required

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 412-

t	Pressure piece -VW 442-

t	Tube -40 - 203/1-

The clutch is only allowed to be dismantled for cleaning or when you are carrying out visual check.

Clutches -K1- and -K3- can be pressed together in some gearboxes.

Pressing -K1- off -K3- → Chapter.

Pressing -K1- onto -K3- → Chapter

1 -	Supporting ring

q	Unclipping from inner disc carrier in 4 pieces.

q	Installing → Fig..

2 -	Inner disc carrier

q	Installing → Fig..

q	Assembling → Fig..

3 -

Circlip

q	Different thickness.

q	Marking after removing and inserting at same point.

4 -	Pressure plate

q	Smooth side faces inner disc.

q	Inserting together with inner disc carrier → Fig..

5 -	Inner disc

q	Quantity → Chapter.

q	Installing → Fig..

q	Before installing place in ATF for 15 minutes.

6 -	Outer disc

q	Quantity → Chapter.

q	Installing → Fig..

q	Always 1.5 mm thick.

7 -	Outer disc

q	Always 2.0 mm thick.

q	Installing → Fig..

8 -	Corrugated washer

9 -

Circlip

q	Removing and installing → Fig..

10 -	Piston cap

q	Sealing lips are vulcanised to cap.

q	Moistening sealing lips with ATF before installing.

q	Turn cap slightly when installing.

11 -	Intermediate spring ring

q	With spring supporting shell and compression springs.

12 -

Piston

q	Sealing lips are vulcanised to piston.

q	Moistening sealing lips with ATF before installing.

q	Turning piston slightly when installing.

13 -	Clutch housing

q	Before inserting the inner disc carrier, place corrugated washer → Item, inner and outer discs into the clutch housing → Fig..

Removing and installing circlip –  Press piston cap with intermediate spring ring down far enough for the circlip -arrow- to be inserted in the groove.

Fitting pressure plate and discs onto inner disc carrier –  Install pressure plate -a- with smooth side facing inner disc and stepped side towards inner disc carrier. –  Install 3 inner discs -b- and 2 outer discs -c- (1.5 mm). –  Clip in supporting ring with step -arrows-. t  Locate locating lugs correctly. t  Installing corrugated washer and further discs in clutch housing → Fig..

Installing corrugated washer and inner and outer discs in clutch housing –  First insert corrugated washer. –  Insert 2 mm thick outer disc. –  Insert remaining inner and outer discs (1.5 mm).

Inserting inner disc carrier and installing circlip -arrow- –  Lift inner disc carrier slightly to install circlip -arrows-.