Dismantling and assembling 1st to 3rd gear clutch -K1- with turbine shaft on gearboxes up to 12.92 — VW

Gearboxes up to 12.92 => Page
00-3

Note:

When performing repairs to the clutch, ensure that the ball valve (arrow) is not damaged.

Supporting ring
4-piece, unclip from inner plate carrier
Inserting =>Fig.
4

Inner plate carrier
Inserting =>Fig.
6
Assembling =>Fig.
4

Circlip
Different thicknesses
Mark after removing and insert in same position

Thrust plate
Smooth side faces inner plate
Insert together with inner plate carrier => Fig.
4

Inner plate
Quantity=> Page
00-3
Insert together with inner plate carrier => Fig.
4

Outer plate
Quantity=> Page
00-3
Insert together with inner plate carrier => Fig.
4

Thrust plate
Curved side to diaphragm spring
Installing=> Fig.
5

Circlip
Installing=> Fig.
3

Diaphragm spring
Insert with curved side to piston

Circlip
Removing and installing =>Fig.
2

Intermediate spring ring
With spring supporting shell and compression springs

Operating ring
Insert with rounded surface facing intermediate spring ring

Disc spring
Curved side faces operating ring
Installation position =>Fig.
1

Disc spring
Curved side faces operating ring
Installation position =>Fig.
1

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

Piston ring (small ø)
Check that it is correctly located
=> Fig.
7
Fitting => Fig.
8

Piston ring
Check that it is correctly located
=> Fig.
7
Fitting => Fig.
8

Clutch housing with turbine shaft
Check bearing bushes. Replace housing if bushes are damaged.
Before inserting the inner plate carrier insert diaphragm spring (item
9
), circlip (item
3
) and one inner and outer plate in the clutch housing =>Fig.
5

Piston ring
Check that it is correctly located
=> Fig.
7
Fitting => Fig.
8

Piston ring
Check that it is correctly located
=> Fig.
7
Fitting => Fig.
8

Piston ring
Check that it is correctly located
=> Fig.
7
Fitting => Fig.
8

Piston ring
Check that it is correctly located
=> Fig.
7
Fitting => Fig.
8

Fig.1
Installation position of disc springs

Install disc springs -1- and -2- so that when placed together the outer edges touch. There is a clearance at the inner diameter.

Fig.2
Removing and installing circlip

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

Fig.3
Inserting circlip

Insert circlip (arrow) in the groove, diaphragm spring is slightly pretensioned.

Fig.4
Placing inner and outer plates on inner plate carrier and clipping in support ring

Insert the thrust plate and the inner and outer plates and then clip supporting ring (arrow) in place.

Note:

An inner and an outer plate must be placed in the clutch housing before inserting the inner plate carrier.

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

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

Lift inner plate carrier slightly to install circlip.

Fig.7
Checking seating of piston rings

There are two piston rings installed on the turbine shaft inside the clutch housing.

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

Fig.8
Fitting and hooking ends of piston ring together

Place piston ring in groove.
To hook ends together press sides of ring in and guide ends over one another.
Do not twist piston ring out of groove on one side.