Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft — VW

Observe general repair instructions=> page
00-24
.

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

VW 401 Thrust plate
VW 402 Thrust plate
VW 407 Press tool
3292/1 From assembly tool 3292

Clutch may be dismantled only for cleaning and visual inspection.

On some gearboxes the clutches -K1- and -K3- may be pressed together.

Pressing -K1- off -K3- => Page
37-112

Pressing -K1- onto -K3- => Page
37-113

Circlip
Different thickness
Mark after removing and insert at same point

Thrust plate
Install with stepped side facing circlip

Inner plate
Quantity=>Page
00-6

Outer plate
Quantity=>Page
00-6

Pressure plate
Install with peened corrugated washer facing piston

Corrugated washer
Peened to pressure plate (item
5
)

Securing ring
Removing and installing => Fig.
1
Different thickness
Mark after removing and insert at same point

Piston cap
Sealing lips are vulcanised to piston cap
Moisten with ATF before installing
Turn piston cap slightly when installing
Removing and installing => Fig.
1

Spring
Seat between piston and piston cap

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

Clutch housing with turbine shaft
There are two different versions => Page
32-1
Height varies according to number of inner and outer plates

O-ring
Always replace
Installing =>Fig.
4

Piston ring
Check that it is correctly located
=> Fig.
2
Removing and installing => Fig.
3

Fig.1
Removing and installing circlip

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

Fig.2
Checking seating of piston rings

There is a piston ring installed on the pump shaft inside the clutch housing (arrow).

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

Fig.3
Removing and installing piston ring

Removing

Press piston ring together and unhook by hand.
Spread piston on both sides and remove. Do not pull out of groove from one side.

Installing

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

Fig.4
Installing O-ring

Insert O-ring in the recess in the turbine shaft (arrow).