1st to 3rd Gear Clutch

Required special tools and equipment:





^ VW 401 Press plate
^ VW 402 Press plate
^ VW 412 Press tool
^ VW 442 Thrust pad
^ 40-203/ 1 Split tube





Note:
Only disassemble clutch when you clean or visually check components.
Clutches -K1- and -K3- are pressed together.
Pressing -K1- off -K3-
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 thicknesses
^ 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 Specifications.
^ Installing refer to Fig. 2
6 Outer plate
^ Quantity. - Refer to Specifications
^ 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 Fig. 1
10 Piston cap
^ Sealing lips are vulcanized to cap
^ Moisten sealing lips with ATF before installing
^ Turn cap slightly when installing
11 intermediate spring ring
^ With spring supporting shell and compression springs
12 Piston
^ Sealing lips are vulcanized to piston
^ Moisten sealing lips 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 far enough down that the circlip -arrow- can be inserted in the 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).

Notes:
^ Position locating lugs correctly.
^ Corrugated washer and inner and outer plates, installing in clutch housing=> Fig. 3.





Fig. 3 Corrugated washer and 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 -white arrows-.