1. to 3rd gear clutch -K1-, dismantling and assembling — VW

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

VW 401 Pressure plate
VW 402 Pressure plate
VW 412 Thrust piece
VW 442 Thrust piece
40-203/1 Tube

Observe general repair instructions => page
00-31
.

The clutch must be dismantled only when cleaning or carrying out a visual check.

The clutches -K1- and -K3- are pressed together.

Pressing -K1- off -K3- => page
37-150

Pressing -K1- on-K3- => page
37-151

Supporting ring
4-part, unclip from inner plate carrier
Installing => fig.
2

Inner plate carrier
Installing => fig.
4
Assembling => fig.
2

Circlip
Thickness varies
Mark after removing and insert in same position

Pressure plate
Smooth side faces inner plate
Insert together with inner plate carrier => fig.
2

Inner plate
Quantity => page
00-6
Installing => fig.
2
Before installing place in ATF for 15 minutes

Outer plate
Quantity => page
00-6
Installing => fig.
2
Always 1.5 mm thick

Outer plate
Always 2.0 mm thick
Installing => fig.
2

Corrugated washer
Circlip
Removing and installing => fig.
1

Piston cap
Sealing lips are vulcanised to the cap
Moisten sealing lips with ATF before inserting
Turn cap slightly when installing

Intermediate spring ring
With spring supporting shell and compression springs

Piston
Sealing lips are vulcanised to the piston
To remove, carefully lever out of clutch bell housing with a screwdriver using several leverage points.
Moisten sealing lips with ATF before inserting
Turn piston slightly when installing

Clutch bell housing
Before inserting the inner plate carrier corrugated washer (item
8
), insert inner and outer plates into the clutch bell housing =>fig.
3

Fig.1
Removing and installing circlip

Press piston cap with intermediate ring down far enough for the circlip (arrow) to be inserted into the groove.

Fig.2
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-.
Clip in supporting ring with step (arrow).

Engage locating lugs correctly.
Installing corrugated washer and further plates into clutch housing => fig.
3
.

Fig.3
Installing corrugated washer and outer and inner plates into clutch bell housing.

First insert corrugated washer.
Insert 2mm thick outer plate.
Insert remaining inner and outer plates.

Fig.4
Inserting inner plate carrier and installing circlip (arrow)

Lift inner plate carrier slightly to install circlip (arrows).