1st to 3rd gear clutch -K1-: disassemble and assemble — VW

VW
Polo
2003
Power transmission
4 - Speed automatic gearbox 001
Edition
10.2004
1
st
to 3
rd
gear clutch -K1-: disassemble and assemble
Check if the clutch works
Fig.
Sealing ring
Remove making a lever with a screwdriver
Pressure disc
Assemble
Fig.
Determine the thickness
Fig.
Internal disc
Assemble
Fig.
Quantity
Chapter
External disc
Assemble
Fig.
Quantity
Chapter
Dish spring
Assemble
Fig.
Sealing ring
Disassemble and assemble =
Fig.
Retainer
Always replace
Plunger cover
Before placing it, apply ATF on the retainers
Spring
Place it between the plunger and the plunger cover
Retainer
Always replace
The sealing lip must be facing the clutch bellhousing
Retainer
Always replace
Plunger
Allocate the spare due to the distinctive letters in the transmission
Assemble
Fig.
Clutch bellhousing with turbine shaft
Segment
Check if it is properly seated
Do not over-expand
Fig.1 - Disassemble and assemble the sealing ring
Push the plunger cover with the spring downward until it is possible to keep the sealing ring in the notch
arrow
.
Fig.2 - Assemble the external and internal discs
The convex side of the dish spring (with small diameter) must be facing the clutch bellhousing.
Place the external discs
2
and the internal discs
4
over the dish spring
3
.
Place the bearing disc
5
over the last internal disc.
Put the sealing ring
1
in the clutch bellhousing notch.
Fig.3 - Determine the bearing disc thickness.
With a gauge "A", measure the oscillation between the bearing disc and the sealing ring.
Component
Gap
Wearing limit
Clutch K1
0,45 ... 0.85 mm
1.05 mm
If the wearing limit is reached with the clutch used, the discs must be changed and a new, proper bearing disc must be selected.
Allocate the discs and the bearing disc due to the distinctive letters in the transmission.
Fig.4 - Check if the clutch works
Before assembling the plunger, apply ATF over the sealing lips and the retainers.
Slightly turn the plunger when assembling it
Once the plunger is assembled in the clutches or the brakes, it must be able to be manually turned easily in both directions
arrows
.
If not, the sealing lips or the retainers may not be completely inserted or are damaged.
Disassemble the plunger if such abnormality occurs.
Check if the sealing lips or the retainers are damaged and change them if necessary
Assemble the plunger and review it again.
Blow compressed air into the pressure channel
arrow
.
Plug the hole in the opposite side.
The clutch plunger must compress the disc pack.
Let compressed air bleed. The disc pack must return to its resting position