Volkswagen Workshop Service and Repair Manuals

Functional check of clutch

=>Fig.4

• Circlip
• ◆ Lever out with screwdriver
• Thrust plate
• ◆ Installing => Fig.2
• ◆ Determining thickness => Fig. 3
• Inner plate
• ◆ Installing => Fig.2
• ◆ Quantity
• Outer plate
• ◆ Installing => Fig.2
• ◆ Quantity=> Page 00-4
• Dished washer
• ◆ Installing => Fig.2
• Securing ring
• ◆ Removing and installing =>Fig.1

• Oil seal
• ◆ Always renew
• Piston cap
• ◆ Moisten sealing ring with ATF before installing
• Spring
• ◆ Seat between piston and piston cap
• Oil seal
• ◆ Always renew
• ◆ Sealing lip faces to clutch housing
• Oil seal
• ◆ Always replace
• Piston
• ◆ Spare part is allocated according to gearbox code letters
• ◆ Installing => Page 38-8
• Clutch housing with turbine shaft
• Piston ring
• ◆ Check that it is correctly located
• ◆ Do not overstretch

→ Fig.1     Removing and installing circlip

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

→ Fig.2     Installing outer and inner plates

Convex side of dished washer (small diameter) faces to clutch housing.

• ‒ Place outer plates -2- and inner plates -4- on the dished washer -3-.
• ‒ Place pressure plate -5- 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 sealing lip and sealing rings with ATF.
• ‒ 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.

• ‒ → Blow compressed air into the pressure channel -arrow-.
• ‒ Keep the drilling on the opposite side closed.
• ‒ The clutch piston must press the plates together.
• ‒ Allow compressed air to escape. The set of plates must return to its rest position.