Volkswagen Workshop Service and Repair Manuals

3rd and 4th gear clutch -K3-: disassemble and assemble When disassembling it, bear in mind the number of discs and their assembly position → Fig. Check if the clutch works → Fig.

1 -	Sealing ring

q	Remove making a lever with a screwdriver

2 -	Bearing 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 -	Sealing ring

q	Disassemble and assemble → Fig.

6 -	Spring holder plate

q	With springs

7 -

Retainer

q	Always replace

8 -

Retainer

q	Always replace

9 -

Plunger

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

q	Assemble → Anchor

10 -	Clutch bellhousing

Fig.1 - Disassemble the sealing ring -arrow- –  Press the plunger cover carefully downward until the sealing ring can be assembled.

Fig.2 - Bear in mind that the number and assembly position of the discs is different. l -  K3- with 3 internal discs ll -  K3- with 4 internal discs A -  Sealing ring

Fig.2 - Assemble the external and internal discs –  Assemble the external discs -4- and the internal discs -3- in the clutch bellhousing. –  Place the bearing disc -2- over the last internal disc. –  Put the sealing ring -1- in the clutch bellhousing notch.

Fig.4 - 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 K3	1,8 ... 2.2 mm	2.4 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.5 - 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. –  Place the clutch -K3- over the transmission case cover and press it downward.

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