Volkswagen Workshop Service and Repair Manuals

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

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 412-

t	Thrust piece -VW 442-

t	Tube -40 - 203/1-

–	Observe general repair instructions → Chapter.

The clutch may be dismantled only for cleaning or carrying out visual check.

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

Pressing -K1- off -K3- → Chapter.

Pressing -K1- onto -K3- → Chapter.

1 -	Support ring

q	Unclip 4 pieces from inner plate carrier.

q	Installing → Fig..

2 -	Inner plate carrier

q	Installing → Fig..

q	Assembling → Fig..

3 -	Retaining ring

q	Different thickness.

q	Mark after removing and insert at same point.

4 -	Pressure plate

q	Smooth side faces inner plate.

q	Insert together with inner plate carrier → Fig..

5 -	Inner plate

q	Quantity → Chapter.

q	Installing → Fig.

q	Lay in → ATF for 15 minutes before installing

6 -	Outer plate

q	Quantity → Chapter.

q	Installing → Fig.

q	Always 1.5 mm thick

7 -	Outer plate

q	Always 2.0 mm thick

q	Installing → Fig.

8 -	Corrugated washer

9 -	Retaining ring

q	Removing and installing → Fig.

10 -	Piston cap

q	Sealing lips are vulcanised to cap.

q	Moisten sealing lips with → ATF before installing.

q	Turn cap slightly when installing.

11 -	Intermediate spring ring

q	With spring support shell and compression springs.

12 -

Piston

q	Using a screwdriver, carefully lever out of clutch housing at several points.

q	Sealing lips are vulcanised to piston.

q	Moisten sealing lips with → ATF before installing.

q	Turn piston slightly when installing.

13 -	Clutch housing

q	Before inserting inner plate carrier, place corrugated spring → Item and inner and outer plates in clutch housing → Fig..

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

Fitting pressure plate and plates onto inner plate carrier –  Install pressure 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- (1.5 mm). –  Clip in support ring with step -arrow-. t  Engage locating lugs correctly. t  Install corrugated washer and further plates in clutch housing → Fig..

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

Inserting inner plate carrier and installing retaining ring -arrow-. –  Lift inner plate carrier slightly to install retaining ring.