1ST to 3RD Gear Clutch -K1-, Disassembling and Assembling

1st to 3rd gear clutch -K1 -, disassembling and assembling, 01M, 4 Spd. A/T

Special tools and equipment required:

- VW 401 Thrust plate
- VW 402 Thrust plate
- VW 412 Press tool
- VW 442 Thrust pad
- 40-203/1 Tube, split





Note:
^ The clutch should only be disassembled for cleaning or to visually check parts.
^ The 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 go to Fig. 2

2 - Inner plate carrier
^ Inserting go to Fig. 4
^ Assembling go 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 go to Fig. 2

5 - Inner plate
^ Installing go to Fig. 2

6 - Outer plate
^ Installing go to Fig. 2
^ Always 1.5 mm thick

7 - Outer plate
^ Always 2 mm thick
^ Installing go to Fig. 2

8 - Corrugated washer
9 - Circlip
^ Removing and installing go to 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 go to Fig. 3.





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





Fig. 2 Installing thrust plate and plates onto 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:
^ Locate tabs correctly.
^ Installing corrugated washer and further plates in clutch housing go to Fig. 3.





Fig. 3 Installing corrugated washer and inner and outer plates in clutch housing
- First insert corrugated washer.
- Insert 2 mm 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).