Dismantling and assembling 1st - 3rd gear clutch -K1- with turbine shaft for gearboxes up to 11.92 — AUDI

Special tools, testers and workshop equipment required

VW 401 Thrust plate
VW 407 Thrust tool
VW 460 Removal device

Notes:

Only when cleaning or carrying out visual check the clutch must be dismantled.

When doing this ensure that the ball valve (arrow) is not damaged.

Supporting ring
Unclip in 4 pieces from inner plate carrier
Inserting
=>Fig.
38-16

Inner plate carrier
Inserting
=>Fig.
38-17
Assembling
=>Fig.
38-16

Circlip
Differing thickness
Mark after removing and insert at same point

Pressure plate
Smooth side faces inner plate
Insert together with inner plate carrier,
=> Fig.
38-16

Inner plate
Number of inner plates => Page
00-3
Installing
=> Fig.
38-16
Before installing place new inner plates in ATF for 15 minutes

Outer plate
Number of outer plates => Page
00-3
Installing
=> Fig.
38-16

Pressure plate
Curved side faces ring tensioning spring
Installing
=> Fig.
38-17

Circlip
Inserting
=> Fig.
38-16

Ring tensioning spring
Curved side faces piston

Circlip
Removing and installing
=>Fig.
38-15

Intermediate spring ring
With spring supporting shell and compression springs

Actuator ring
Insert with curvature facing spring spacer

Dished washer
Convex side faces actuator ring
Installation position
=>Fig.
38-15

Dished washer
Curved side faces piston
Installation position
=>Fig.
38-15

Piston
Sealing lips are vulcanised to piston
Moisten sealing lips with ATF before installing
Turn piston slightly when installing

Piston ring (small dia.)
Checking correct positioning
=> Fig.
38-18
Removing and installing
=>Fig.
38-18

Piston ring
Checking correct positioning
=> Fig.
38-18
Removing and installing
=>Fig.
38-18

Clutch housing with turbine shaft
Check mounting bushes; replace clutch housing if bushes damaged
Before fitting inner plate carrier, insert ring tensioning spring (item
38-17

Piston ring
Checking correct positioning
=> Fig.
38-18
Removing and installing
=>Fig.
38-18

Piston ring
Checking correct positioning
=> Fig.
38-18
Removing and installing
=>Fig.
38-18

Piston ring
Checking correct positioning
=> Fig.
38-18
Removing and installing
=>Fig.
38-18

Piston ring
Checking correct positioning
=> Fig.
38-18
Removing and installing
=>Fig.
38-18

Fig.1
Installation position of dished washers

Fit dished washers 1 and 2 such that outer edges make contact when fitted together; air gap remains in inside diameter.

Fig.2
Removing and installing circlip (arrow)

Press spring ring down far enough for the circlip (arrow) to be inserted in the groove.

Fig.3
Inserting circlip

Insert circlip (arrow) in groove; ring tensioning spring is slightly pretensioned.

Fig.4
Positioning inner and outer plates on inner plate carrier and clipping in thrust bearing

Clip in thrust bearing (arrow) after inserting pressure plate as well as inner and outer plates.

Note:

The inner and one outer plate must be inserted in clutch housing before fitting inner plate carrier.

Fig.5
Inserting pressure plate, first inner plate and first outer plate in clutch housing

Fig.6
Inserting inner plate carrier and installing circlip (arrow).

Lift inner plate carrier slightly to fit circlip.

Fig.7
Checking seating of piston rings

Ensure that the ends of the piston rings are hooked together.

Fig.8
Removing and installing piston ring

Removing

Press ends of piston ring together and release by hand.
Press two ends of piston ring apart and remove; do not twist piston ring out of groove on one side.

Installing

Place piston ring in groove.
To hook ends together press sides of ring in and guide ends over one another.