Volkswagen Workshop Service and Repair Manuals

Take note of number of plates and location during dismantling stage => figure 2 .

Functional check of clutch

=>Fig.5

• Circlip
• ◆ Lever out with screwdriver
• Thrust plate
• ◆ Installing => Fig.3
• ◆ Determining thickness => Fig. 4
• Inner plate
• ◆ Installing => Fig.3
• ◆ Quantity
• Outer plate
• ◆ Installing => Fig.3
• ◆ Quantity

• Securing ring
• ◆ Removing and installing => Fig.1
• Spring supporting plate
• ◆ With springs
• Oil seal
• ◆ Always replace
• Oil seal
• ◆ Always renew
• Piston
• ◆ Spare part is allocated according to gearbox code letters
• ◆ Installing
• Clutch housing

→ Fig.1     Removing and installing circlip (arrow)

• ‒ Press down carefully on piston cap until the circlip an be installed.

→ Fig.2     Observe different number and location of plates

I - -K3- with 3 inner plates

II - -K3- with 4 inner plates

A - Circlip

→ Fig.3     Installing outer and inner plates

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

→ Fig.4     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 anew pressure plate must be calculated.
• ‒ Allocate plates and pressure plate according to gearbox code letters.

→ Fig.5     Functional check of clutch

• ‒ Before installing the piston moisten sealing lips 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.
• ‒ Place clutch -K3- on gearbox housing cover 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.