1st to 3rd Gear Clutch -K1-

Special Tools And Equipment
^ VW 401 Press plate
^ VW 402 Press plate
^ VW 412 Press tool
^ VW 442 Thrust pad
^ 40-203/1 Tube, split

Note:
^ Only disassemble clutch when cleaning or visually checking components.
^ Clutches -K I-and -K3- are pressed together.
^ Pressing -K1- off -K3- Refer to Automatic Transmission/Transaxle; Service and Repair.
^ Pressing -K1- onto -K3-





1. Supporting ring
^ 4-piece, unclip from inner plate carrier
^ Inserting refer to Fig. 2
2. Inner plate carrier
^ Inserting refer to Fig. 4
^ Assembling refer to Fig. 2
3. Circlip
^ Different thickness
^ Mark after removing and insert in same position
4. Thrust plate
^ Smooth side faces inner plate
^ Insert together with inner plate carrier refer to Fig. 2
5. Inner plate
^ Quantity. Refer to Application and ID.
^ Installing refer to Fig. 2
6. Outer plate
^ Quantity Refer to Application and ID.
^ Installing refer to Fig. 2
^ Always 1.5 mm thick
7. Outer plate
^ Always 2 mm thick
^ Installing refer to Fig. 2
8. Corrugated washer
9. Circlip
^ Removing and installing refer to Fig. 1
10. Piston cap
^ Seals are vulcanized to cap
^ Moisten seals with ATF before installing
^ Turn cap slightly when installing
11. Intermediate spring ring
^ With spring supporting shell and compression springs
12. Piston
^ Seals are vulcanized to piston
^ Moisten seals with ATF before installing
^ Turn piston slightly when installing
13. Clutch housing
^ Before inserting inner plate carrier corrugated washer (item 8), insert inner and outer plates in clutch refer to Fig. 3





Fig. 1 Circlip, removing and installing
- Press piston cap with intermediate spring ring down far enough for circlip (arrow) to be inserted in groove.





Fig. 2 Thrust plate and plates, installing on inner plate carrier
- Install thrust plate -a- with smooth side facing inner plate and stepped side toward inner plate carrier.
- Install 3 inner plates -b- and 2 outer plates -c-.
- Clip in supporting ring with step (arrow).

Note:
^ Position locating lugs correctly.
^ Corrugated washer, inner and outer plates, installing in clutch housing refer to Fig. 3.





Fig. 3 Corrugated washer, inner and outer plates, installing in clutch housing
- First insert corrugated washer.
- Insert 2 mm thick outer plate.
- Insert remaining inner and outer plates.





Fig.4 Inner plate carrier and circlip (arrow), installing.
- Lift inner plate carrier slightly to install circlip (arrows).