3rd and 4th gear clutch -K3-: disassemble and assemble — VW

VW
Polo
2003
Power transmission
4 - Speed automatic gearbox 001
Edition
10.2004
3rd and 4th gear clutch -K3-: disassemble and assemble
When disassembling it, bear in mind the number of discs and their assembly position
Fig.
Check if the clutch works
Fig.
Sealing ring
Remove making a lever with a screwdriver
Bearing disc
Assemble
Fig.
Determine the thickness
Fig.
Internal disc
Assemble
Fig.
Quantity
Chapter
External disc
Assemble
Fig.
Quantity
Chapter
Sealing ring
Disassemble and assemble
Fig.
Spring holder plate
With springs
Retainer
Always replace
Retainer
Always replace
Plunger
Allocate the spare due to the distinctive letters in the transmission
Assemble
Anchor
Clutch bellhousing
Fig.1 - Disassemble the sealing ring
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Press the plunger cover carefully downward until the sealing ring can be assembled.
Fig.2 - Bear in mind that the number and assembly position of the discs is different.
l
K3- with 3 internal discs
ll
K3- with 4 internal discs
A
Sealing ring
Fig.2 - Assemble the external and internal discs
Assemble the external discs
4
and the internal discs
3
in the clutch bellhousing.
Place the bearing disc
2
over the last internal disc.
Put the sealing ring
1
in the clutch bellhousing notch.
Fig.4 - 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 K3
1,8 ... 2.2 mm
2.4 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.5 - 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
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.
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.
Place the clutch -K3- over the transmission case cover and press it downward.
Blow compressed air into the pressure channel
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.
The clutch plunger must compress the disc pack.
Let compressed air bleed. The disc pack must return to its resting position.